GE Power Powering the World Responsibly ge.com Powering the World STEAM POWER SYSTEMS PRODUCT CATALOG
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Poweringthe WorldSTEAM POWER SYSTEMS PRODUCT CATALOG
Delivering highly efficient and cleaner power generationThe availability and affordability of coal makes it a critical fuel in a world that is
striving to meet the energy needs of tomorrow. Coal and oil fired power plants are
well positioned to deliver additional capacity to growing regions of the world as long
as we use our best technology to lessen the related environmental impact. If anyone
is up for the challenge, we are.
At GE’s Steam Power Systems we use our unrivalled expertise every day to help
customers get tailored systems that stand the test of time, while continually driving
improved efficiency and performance benchmarks.
We offer customers exceptional flexibility. From a single component to a full power
plant — our broad range of products covers a large scope of applications and a wide
range of fuels including coal, lignite, anthracite and petcoke. We put over 100 years
of steam power expertise to work, generating power that is reliable, efficient, easy to
integrate and operate.
Our customers can count on us to help them deliver as much energy as possible,
to the greatest number of people, in the most efficient way. Our relationship goes
beyond the technology or our team of experts; it’s a partnership based on a shared
commitment to make sustainable power possible for people around the world, and
right around the corner.
© 2015, General Electric Company and/or its affiliates. GE Proprietary Information. All Rights Reserved. No part of this document may be reproduced, transmitted, stored in a retrieval system nor translated into any human or computer language, in any form or by any means, electronic, mechanical, magnetic, optical, manual, or otherwise, without the prior written permission of the General Electric Company or its concerned affiliate.
Industry Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Key Differentiators. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Technology Leadership . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
The Plant Integrator Approach. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Standardized/Pre-Engineered Solutions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Flexible Offerings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Power Plant Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Boilers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Steam Turbines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Generators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Air Quality Control Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
CO2 Capture Solutions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
CONTENTS
Information contained in this document is indicative only. No representation or warranty is given or should be relied on that it is complete or correct or will apply to any particular project. This will depend on the technical and commercial circumstances. It is provided without liability and is subject to change without notice.
40%
35%
15%
5%Europe (ind. Turkey)
North America
Latin America
Oceania
Russia and CIS
Middle East and Africa
Asia (exd. China and India)
India
China
Bituminous
Sub-bituminous
Lignite
NOTE: Reserve �gures in trillions tonnes
NAM 270
LAM 18
Africa 55
Oceania 85
India 62
China 126
Russia 173
RoA 12
Europe 48
An Essential Role in the Global Power MixCoal power is the most mature and the most common power generation technology in the world.
With 2,550 GW of installed capacity providing 41 percent of the global electricity supply, coal serves
as the reliable, cost-effective and durable baseload power source to utility scale networks.
Coal resources are broadly distributed around the globe and are often locally available. At current
consumption rates coal reserves should last for centuries. The use of coal for power generation can
also offer energy security by reducing dependence on more restricted fuel supplies.
2 3
STEAM POWER SYSTEMS PRODUCT CATALOG I Global Overview
COAL POWERIndustry Overview
2,550 400 1,440 1,855
10,000 2,550 5,050 6,050
InstalledBase (GW)
ElectricityGenerated (TWh)
6,245 GW
23,650 TWh
Coal Nuclear Gas Other
41% 7% 23%
42% 11% 21%
30% Total Worldwide
26%
Coal Power Market for the Next 10 Years
25%of all future power capacity additions will be coal- or oil-fired steam power plants
95%of the global demand will come from fast-growing economies in India, China, Asia, the Middle East and Africa
Coal ReservesCapacity Additions
Market Drivers• Affordable energy• Available and reliable supply• Fuel flexibility• Emissions regulations
Reducing Emissions to Mitigate Global Environmental ConcernsGE’s Steam Power Systems is an industry leader in cleaner power generation from coal and oil. Stringent regulations to limit emissions have been deployed, revised and reinforced for decades. The U.S. and parts of Europe have strict emission regulations in place, while China has implemented, and India is developing, environmental control strategies to cope with booming development of their coal-based industries.
With more than 80 years of experience providing Air Quality Control Systems (AQCS), GE has the expertise, technology and extended product portfolio to reduce gaseous emissions from coal (or oil) combustion and meet today’s most stringent emission requirements.
To reduce CO2 emissions, GE is contributing on two major fronts. First, GE has designed, installed and commissioned many of the highest efficiency coal and oil plants in the world, which not only optimize the operating costs (reduced fuel consumption per MW produced) but also reduce the CO2 emitted per MW produced. Second, GE has developed and industrially tested CO2 Capture solutions which are fully ready for large-scale deployment.
Highly efficient power generation from coal and oil
The demand for new coal power plants in the next 10 years will come predominantly from the prospering emerging regions of the world.
* Source Alstom, Status end of 2014
Widely dispersed and abundant coal resources provide a highly secure supply for coal power generation.
Powering the World
4 5
STEAM POWER SYSTEMS PRODUCT CATALOG I Technology Leadership
GE has the expertise and resources to meet specific customer needs with a portfolio of products covering
commonly used fuels for power generation. With fossil fuel power plants likely to continue as the
main providers of global power generation, the efficient and reliable conversion of fuel into electricity will
remain critically important.
Efficiency IncreaseAt GE, we are always working to lower fuel consumption and emissions by increasing power plant efficiency. Our advanced power plants use ultra-supercritical technology. Other improvements in power plant efficiency include:
• Double-reheat technology
• Cold end advancement
• Flue gas heat recovery systems
To optimize the thermodynamic cycle, we have enhanced the design of each component to improve overall efficiency of the plant.
Future developments from GE include advanced USC (>700°C) technology and pre-drying technology for high-moisture lignite.
Proven Fuel ExpertiseOur cleaner combustion technologies:
• Cover a large spectrum of fuels, from bituminous to lignite coals to oil and gas, heavy residues, biomass, and others
• Have experience with the most difficult fuels (e.g. Oil Shale, VRO, high-moisture, etc.)
• Are designed to remain insensitive to variations in fuel composition
Operational Flexibility and ReliabilityOur products deliver high operational flexibility to accommodate the growing requirements of power generation from renewables.
Experience derived from a huge installed fleet helps us to continually improve our products and increase their operational reliability.
Our products and designs deliver high availability and easy maintenance for:
• Shorter planned outages
• Reduced life-cycle costs in the power station
Emissions ReductionTo lower the impact of power generation to the environment, our AQCS products enable power plants to conform to today’s strict environmental standards for air emission levels.
In addition, we have developed a portfolio of technologies for CO2 capture that includes pre- and post-combustion processes suitable for new builds as well as the retrofit of existing plants.
GE’s Advanced USC Developments
Today
Cha
nge
in o
vera
ll p
lant
net
e�
cien
cy (r
elat
ive)
+4.0%
+6.0%+6.7%
+8.7%
+11.3%
170 bar540°C540°C
Sub-critical
Baseline240 bar565°C565°C
Supercritical
260 bar600°C600°C
275 bar600°C620°C
300 bar600°C
620/620°C
350 bar700°C720°C
Ultra-Supercritical Double reheat 700+°C
FIRSTWorld’sUSC50 YEARS OF OPERATION
At Eddystone PlantPhiladelphia, PA USA
202,000MWeor 313 boilers installedusing USC technology
36%of our steam turbinesin the last 10 years
are USC
Delivering High Efficiency Coal Power to Our Customers Globally• 912 MW USC, Germany: greater than
46 percent net efficiency
• 911 MW USC with CHP, Germany: flexible
energy production (electricity + district heating
+ railway power) resulting in fuel utilization
up to 70 percent efficiency
• 1,080 MW USC, Malaysia: the first USC 1,000
MW-class plants in Southeast Asia. Efficiency
over 43 percent (at local cooling temperatures)
Powering the World
Key Differentiators
TECHNOLOGY LEADERSHIP
912 MW USC, Germany
Our Plant Integrator approach is based on our ability to combine GE’s components and auxiliary equipment into fully enhanced and integrated systems. The return of experience from manufacturing, construction, commissioning and operation results in a systematic continuous improvement of GE’s components and standardized/pre-engineered solutions. This leads to improved performance, as well as cost and delivery time reduction of our offering to our key markets and helps our customers achieve and exceed their objectives.
Unique Integration Capabilities• Broad in-house product portfolio – all major plant components jointly developed to work as one unit
• Demonstrated high efficiency plants meeting local requirements
• Flexible offerings – from single OEM components up to full turnkey power plants
• Global flue gas chain management from boiler to stack – controlled emission footprint
Extensive Execution Experience• 100 years of experience – in building steam power plants, making GE a global leader
>100 GW installed integrated power >200 integrated projects executed globally
• Attuned to the local codes/standards
Continuous Improvement – Via Focus and Extensive Return of Experience
6 7
STEAM POWER SYSTEMS PRODUCT CATALOG I Plant Integrator Approach
Key Market Segments (local customer requirements)
Standardized/Pre-Engineered Solutions (focused product development)
Integrated Execution (overall performance
responsibility)
Flexible O�erings (improved components and
integrated solutions)
Integration(added value) Sustainable customer value and
excellence in project execution
Powering the World
Key Differentiators
PLANT INTEGRATOR* APPROACH
8 9
STEAM POWER SYSTEMS PRODUCT CATALOG I Standardized/Pre-Engineered Solutions
GE has a systematic approach to developing standardized and pre-engineered components and power plant designs, while keeping sufficient flexibility to meet our customers’ needs. This approach enables us to improve the manufacturing, assembly, construction, commissioning, operation and maintenance of the power plant, which results in improved reliability and availability of our offerings.
Integrated Steam Platforms (ISP)For each major segment of the market, GE has created a pre-engineered plant approach which delivers solutions matching the specific needs coupled with competitive cycle times during offering and execution phases. These Integrated Steam Platforms (ISP) make extensive use of standardization and design-to-cost, while still maintaining sufficient flexibility to meet individual project requirements. The benefits of this approach to our clients are multifold:• Built-in flexibility: to address most of the site and project specific conditions (fuels, codes and standards, cooling
media, emission limits)• Improved quality: Re-use of proven solutions and design principles combined with continuous improvement,
systematic return-of-experience, and lessons learned from tendering, engineering and execution• Improved health and safety: Safer to construct and safer to operate• Reduced delivery times: Quicker response to customer requests during the tender phase, and
reduced construction and commissioning time• Operation and maintenance: Faster to maintain, leading to improved availability• Emissions Regulations: Each ISP is capable of meeting today’s most stringent local, regional or global
emissions requirements
1 State-of-the-art steam technology today; 2 Steam parameters at boiler outlet, typical values; 3 Efficiency values based on LHV basis and typical regional vacuum pressure.Values in table indicate pre-engineered solutions to meet local requirements, adaptions foreseen on project basis
GE’s Integrated Steam Platforms (ISP) for today’s competitive environment … and a sustainable future
Generator• Standardized and reliable product families related to cooling technologies• Common technologies, manufacturing processes, tools and materials
Air Quality Control Systems (AQCS)• Standardized components, processes and tools• Parametric designs for �exibility to meet environmental requirements
Steam Turbines• Global modular approach of the steam turbine frames with standardized interfaces• Flexibility in the steam path design
Boiler Island• Standardized steel structure designs, components and piping sizes• Standardized heating surface components across power output range
Global Product Standardization Initiatives
Turbine Island• Globalized design by freezing positions and dimensions with speci�c variants• Increased design commonality
Integrated Steam Platform• Designed for local requirements• Can consist of pre-engineered solutions of the following o�erings
Turnkey Power BlockTurbineIsland
i.PP(Integrated Power
Package)
Stand-Alone
Components
ISP Europe 900
Asia 660
Asia 1100
India 660
India 800
Fuel TypeDomestic/Imported Bituminous and Sub-Bituminous Coal
Domestic/Imported Bituminous and Sub-Bituminous Coal
Domestic/Imported Bituminous and Sub-Bituminous Coal
Domestic/Imported Bituminous and Sub-Bituminous Coal
Domestic/Imported Bituminous and Sub-Bituminous Coal
Gross Power Output (MW) 900 660 1100 660 800
Water/Steam Cycle1 Ultrasupercritical Ultrasupercritical Ultrasupercritical Ultrasupercritical Ultrasupercritical
Live Steam Pressure (bar)2 ≤ 294 ≤ 294 ≤ 294 ≤ 294 ≤ 294
Live Steam Temperature (°C)2 ≤ 605 ≤ 605 ≤ 605 ≤ 605 ≤ 605
Hot Reheat Temperature (°C)3 ≤ 623 ≤ 623 ≤ 623 ≤ 623 ≤ 623
Net Plant Efficiency (%)3 ≤ 46.3 ≤ 43.5 ≤ 43.5 ≤ 43.0 ≤ 43.0
Boiler Type (typical) Tower Two-Pass Two-Pass Two-Pass Two-Pass
Cooling Technology direct / cooling tower direct / cooling tower direct / cooling tower direct / cooling tower direct / cooling tower
Vacuum Pressure (mbar) 20 - 30 60 - 80 60 - 80 70 - 100 70 - 100
Number of preheaters 9 8 8 8 8
Feedwater pump drive (typical) motor motor / turbine turbine turbine turbine
Powering the World
Key Differentiators
STANDARDIZED/PRE-ENGINEERED SOLUTIONS
FLEXIBLE OFFERINGSFreedom to Fulfill Individual Customer Requirements
10 11
STEAM POWER SYSTEMS PRODUCT CATALOG I Flexible Offerings
The OEM with the full in-house product capability from conceptualization to final design
Powering the World
GE applies the concept of flexible offerings across our portfolio, allowing our customers to select from a portfolio of products and systems that meet their specific requirements, while maintaining the key benefits of standardization and pre-engineering processes. In addition, GE’s Plant Integrator* approach can deliver added value across the full range of offerings.
Integrated Offerings - Flexible ScopeFrom the basic engineering of our core components in our Integrated Power Package (i.PP) to the full turnkey plant, GE can address all customer needs.
Integrated Offerings - Flexible OutputFrom individual components to the full turnkey plant, GE provides integrated offerings for power output from 100 MW to 1,200 MW across a wide range of fuels for steam power generation.
COMPONENTSINTEGRATED
POWERPACKAGE
FULL TURNKEYPLANTS
POWERBLOCK
TURBINEISLAND
PLANT INTEGRATOR*
Boiler Types Power Output Range (MW)
300–1,200 MW
100–660 MW
400–800 MW
Pulverized Coal (PC)
Circulating Fluidized Bed (CFB)
Heavy Fuel Oil (HFO)
Whether you are a power plant owner or an EPC contractor, sourcing the main power generation
equipment for your new build is the most important decision you will make. GE’s Integrated Power
Package (i.PP) supplies our customers with our world-class boilers, and turbines, all of which have
been conceptualized to operate as one unit, allowing us to provide excellent performance and power
output. With our flexible offerings concept, customers can add additional GE equipment, providing them
with enhanced quality and performance.
12 13
STEAM POWER SYSTEMS PRODUCT CATALOG I Flexible Offerings
Saudi Arabia5 x 620 MW Integrated Power Package (i.PP)
Product620 MW supercritical heavy fuel oil (HFO) and gas-fired (dual fuel) power plantScopeIntegrated Power Package (i.PP) including AQCS— Boiler, steam turbine, generator— Electrostatic precipitators and flue gas desulfurization system— Basic engineering of the power block— Advisory and site services— CommissioningBenefits• Overall performance and emission guarantees (power output,
heat rate, emissions)• Steam extracton for desalination
Saudi Arabia’s first supercritical power plant to run on HFO
Basic i.PP Offering
+Integration
(basic engineering and functional specifications for power block)
+Overall Performance Guarantee
(power output, heat rate, emissions)
Integrated Power Packages – ideal solution for competitive EPC contractors
Contributes to 90 percent of the plant performance, using just the core OEM components
Boiler (core parts): (all pressure parts, the firing system, mills)
Steam Turbine,Generator,
AQCS (optional)
Powering the World
Flexible Offerings
INTEGRATED POWER PACKAGE (i.PP)
The turbine island is one of the most critical parts of the power plant, and of prime importance is
the integration of key parameters and interfaces among the auxiliary components and steam water
cycle. With proven equipment and systems, the plant is able to consistently deliver the desired output
throughout the product’s life cycle. GE’s flexible offering allows for excellent layout of the turbine hall,
providing significant savings in construction and labor costs.
14 15
STEAM POWER SYSTEMS PRODUCT CATALOG I Flexible Offerings
India7 x 660 MW SC Turbine Islands
Product660 MW Turbine IslandScope• Steam turbine and auxiliary equipment• Generator and auxiliary equipment• Condensate system• Feed water system• Control, protection and instrumentation• Construction and commissioningBenefitsIntegrated and enhanced systems meeting Indian requirements
Steam Turbine, Generator,Heat Exchangers
Scope of Offering
+Balance of Turbine Island
(feedwater pumps or turbines, piping, valves, control systems)
+Integration, Construction and
Commissioning, O&M
+Overall Performance Guarantee
(power output, heat rate)
Providing critical OEM steam turbine, generator and enhanced water steam cycle interfaces
Powering the World
Flexible Offerings
TURBINE ISLAND
One of the most complicated and critical challenges of integration in a plant is the power block.
The power block consists of the power plant’s critical equipment including boiler, steam turbine,
generator, air quality control systems and associated auxiliary systems. Integration is key to plant
performance over its lifetime and provides a quicker and lower risk return on investment. However,
successful integration requires a global footprint and world-class EPC capabilities. GE’s competitive
power block offering is based on our extensive global experience integrating key components with varied
scope of supply and our proven solutions.
16 17
STEAM POWER SYSTEMS PRODUCT CATALOG I Flexible Offerings
Poland2 x 930 MW USC Power Block
Product930 MW coal-fired, ultra-supercritical power plantScope• Boiler island including FGD and ESP• Turbine island including turbine hall equipment• Balance of Power Block (BoPB)• Construction and commissioning supportBenefits• High efficiency (approximately 45.5 percent)• Meets stringent European emissions regulation:
sulfur dioxide (SOx), nitrogen oxides (NOx) and particulate matter
Poland’s largest coal-fired power plant
Full Boiler Island, Full Turbine Island AQCS Equipment (optional)
Scope of Offering
+Balance of Power Block
(service systems: cooling water, compressed air, HVAC, fire fighting, electrical building and transformers)
+Integration, Construction and
Commissioning, O&M
+Germany1 x 912 MW USC Power Block
Product912 MW coal-fired, ultra-supercritical power plantScopeFull turnkey power blockBenefits• Overall net plant efficiency of more than 46 percent
(greater than 58 percent with district heating)• Meets stringent European emissions regulation:
— CO2 < 740 g/kWh
— CO and NOx < 100 mg/Nm3
One of the highest efficiency steam power plants in the world
Overall Performance Guarantee(power output, heat rate, emissions)
Design and integration of all critical equipment and systems at the power plant level
Powering the World
Flexible Offerings
POWER BLOCK
Today’s plant owners and power operators know that it takes more than selecting a set of high efficiency
components to achieve advanced economic and technical goals. In order to maximize long-term returns on
investment, it takes a company like GE, with extensive experience and world-class EPC capabilities – such
as project management, logistics, and construction management. GE’s range of capabilities in design and
integration of steam power plant solutions gives us a unique perspective that allows us to analyze the
entire plant over its full life cycle as an integrated system.
18 19
STEAM POWER SYSTEMS PRODUCT CATALOG I Flexible Offerings
Malaysia2 x 1,080 MW USC Coal Plant
Product1,080 MW coal-fired, ultra-supercritical power plantScopeTurnkey EPC contract with consortium partnerBenefits• Additional capacity to meet strong demand in
fast-growing economy• Continued relationship between customer and GE following successful
supply of three previous units
Malaysia’s first ultra-supercritical coal-fired unitsFull Power Block
Scope of Offering
+Balance of Plant
(water intake, polishing unit, stack, cooling tower, fuel systems, coal/ash handling, switchyard)
+Integration, Construction and
Commissioning, O&M
+Poland1 x 858 MW USC Lignite Plant
Product858 MW coal-fired, ultra-supercritical power plantScopeFull turnkey steam power plantBenefits• Higher efficiency (close to 42 percent)• Lower emissions of sulfur dioxide (SOx) and nitrogen oxides (NOx)
Poland’s largest and most efficient lignite-fired plant
Overall Performance Guarantee(power output, heat rate, emissions)
Providing the full GE advantage with enhanced economics, shorter lead times, extended performance and reduced O&M costs over the life cycle of the plant
Powering the World
Flexible Offerings
FULL TURNKEY PLANT
21
BOILERSPortfolio and Overview
20
STEAM POWER SYSTEMS PRODUCT CATALOG I Boilers
Two-Pass Tower CFB
CO
AL
Lignite B
Lignite A
Subbit. C
Subbit. B
Subbit. A
Bit. High Vol. C
Bit. High Vol. B
Bit. High Vol. A
Bit. Med. Vol.
Bit. Low Vol.
Semi-Anthracite
Anthracite
Meta-Anthracite
OIL
Heavy Fuel Oil
Vacuum Residual Oil
Crude Oil
GA
S
Natural Gas
Coke Oven Gas
Blast Furnace Gas
OP
PTY
. FU
EL
Biomass
Oil Shale
Petcoke
Waste Coal
Unparalleled Fuel ExpertiseOur knowledge of fuels
and combustion, a core GE
competence, is derived from
our extensive laboratory and
field experience. With these
technologies, our customers
can burn a wide spectrum of
fuels, from high-rank coals
to low-rank coal wastes, and
from oil and natural gas to
opportunity fuels such as
petroleum coke, biomass
and oil shale. With our leading
technologies and a globally
proven product portfolio,
GE provides excellent fuel
firing flexibility that can
lower the cost of electricity
for our customers.
* SHO temperature/RH temperature/SHO pressure
GE’s boiler technology has a heritage of more than 100 years, and our installed base of utility boilers
makes up about 30 percent of all boilers installed or under construction worldwide. As an industry
leading supplier of efficient, flexible and reliable boilers for power generation, GE offers both two-pass
and tower designs that can burn a wide range of hard coals, lignite, and oil/gas, and offers circulating
fluidized bed boilers for both conventional and difficult-to-burn fuels.
Full Boiler Product Portfolio
Two-Pass Boiler Tower Boiler CFB Boiler
TYP
ICA
L FU
ELS
• Bituminous, sub-bituminous• Lignite A• Oil and gas
• Bituminous, sub-bituminous• Lignite A and B
• Anthracite through lignite A and B
• Opportunity fuels: petroleum coke, biomass, waste coal, oil shale, etc.
CA
PAC
ITY
• Up to 1,350 MWe • Up to 605°C/623°C/300 bar*
• Up to 1,350 MWe • Up to 605°C/623°C/300 bar*
• Up to 660 MWe for lignite, higher for hard coal
• Up to 605°C/623°C/285 bar*
FEA
TUR
ES/
AD
VAN
TAG
ES
• Most commonly used technology• Specialized for oil and gas firing• Faster construction with
simultaneous construction on both passes
• Simple roof penetration
• Especially designed to burn high moisture lignite
• Simple and reliable design• Faster startup• Smaller footprint
• Suited to low-grade fuels • Can simultaneously burn
different fuels• No need for SCR and WFGD• Higher reliability with
modular design
Flexible Scope of SupplyGE has a full range of boiler offerings, from boiler to complete boiler island configurations, depending
on our customers’ specific project needs.
Efficient, flexible, reliablesteam generation
Powering the World
Co-firing in limited amountsTower boiler is capable of oil and gas firing if requested by the customer.
STEAM POWER SYSTEMS PRODUCT CATALOG I Boilers
2322
Tangential Firing SystemGE introduced the tangential firing system in 1927. Fuel and air are injected through windboxes from the
corners of the furnace, aimed tangent to an imaginary circle in the center of the furnace. This creates a
single rotating flame envelope (vortex) that produces a uniform and consistent heat profile across the
furnace walls over the operating load range. Due to aerodynamics, the fuel and air are mixed throughout
the furnace, resulting in high efficiency combustion. Tangential firing also provides the following
advantages for GE’s two-pass and tower boiler designs:
Industry Leader in Supercritical and High EfficiencyGE led the industry in developing supercritical steam generation technology, and is an industry leader in today’s high efficiency ultra-supercritical technology. Our expertise in thermal, hydraulic, and material sciences has led to boiler designs that offer tremendous improvements in steam parameters. Advanced tangential firing systems can lower exhaust gas emissions, providing an additional benefit as countries seek to lower emissions.
High EfficiencyGE’s ultra-supercritical boilers contribute to cycle efficiencies of 42 to 45 percent on an HHV basis (44 to 47 percent LHV basis), significantly reducing both fuel and emission control costs for our customers.
Extensive Experience and ReferenceTo date, GE has directly supplied more than 116,000 MW of supercritical/ultra supercritical boilers worldwide, and has licensed and trained other companies to install an additional 140,000 MW.
Continuous DevelopmentGE continues to invest significantly in research and development dedicated to improving our high efficiency power generation equipment.
• Ultra-supercritical circulating fluidized bed (USC CFB): With our world-class experience in ultra-supercritical pulverized coal boilers and expertise in the design of CFB firing, GE has developed highly efficient ultra-supercritical CFB technology, which provides reliable and fuel-flexible power generation with a lower CO2 footprint.
• Double reheat (DRH): GE has supplied double reheat boilers for more than 50 years, and today we offer USC double reheat configurations for both tower and two-pass boiler designs.
• Advanced ultra-supercritical (A-USC): GE is in collaboration with various groups in Europe (700°C) and the U.S. (760°C) for A-USC steam cycle development.
Efficiency Improvement with Increasing Steam Conditions
Powering the World
BOILERSPortfolio and Overview
Steam conditions in bar/ºC/ºC (psi/ºF/ºF)
167/540/540(2,400/1,000/1,000)
240/540/565(3,500/1,000/1,050)
275/580/600(4,000/1,075/1,100)
275/600/620(4,000/1,100/1,150)
375/700/720(5,400/1,300/1,325)
375/730/760(5,400/1,330/1,400)
R&D ongoing USA USC Materials Consortium & ECAD 700 Project (Ni-base)
1960 1980 2000 2020
SUBCRITICALSUPERCRITICAL
ULTRA-SUPERCRITICAL (USC)
ADVANCED USC
• Low primary NOx emissions for decreased SCR catalyst
volume, reagent use, and maintenance requirements
• Efficient use of furnace volume, resulting in reduced slagging
tendency and soot-blowing frequency
• Excellent flame stability for increased unit turndown and
a wider latitude for fuel property variation
• Tilting capability resulting in no attemperation for reheat
temperature controls
2524
STEAM POWER SYSTEMS PRODUCT CATALOG I Boilers
Ultra-supercritical CFB660 MWe for lignite B, higher for hard coal
• Ultra-supercritical 285 bar, 605°C/623°C (MS/RH)
• More than three points increased net plant
efficiency relative to subcritical
• Six percent reduction of CO2 footprint
• Inherent low NOx emission with our air staging
• Low SO2 emission without backend treatment
• Designed for reliability:
— Well-tested material for pressure parts with
many years of onsite experience
— Multiple fuel feeders and ash extraction ports
— Standardized modules that allow changing
outputs, fuels and steam temperatures
With no additional flue gas treatment as SCR and WFGD
Emissionsmg/Nm3
@ 6% O2 dg ppm lb/mm Btu
NOx 150 75 0.12
SOx 200 70 0.16
Lignite B India Malaysia Turkey Germany Poland Hungary Indonesia
Moisture (%) 58 50 46 60 46 48 55
Ash (%) 6 8 13 5 11 20 4
VM daf basis (%) 54 51 51 54 56 65 59
Sulfur (%) 0.5 0.4 2.0 0.2 0.4 1.5 0.1
HHV af basis (mBtu/lb) 4.2 4.7 5.6 4.3 5.9 4.4 4.8
LHV ar (Mcal/kg) 1.8 2.1 2.3 1.8 2.5 1.6 2.1
Typical lignite analyses used for sizing the 660 MW CFB-firing system
Typical emissions:
Powering the World
Cleaner, efficient, flexible, reliable, steam generation for all type of fuels
BOILERSPortfolio and Overview
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Coal-fired Two Pass Oil and Gas–fired Two Pass
Fuel • Bituminous
• Sub-bituminous
• Lignite A
• Oil (Heavy Fuel Oil, No. 2 Oil, No. 6 Oil, Crude Oil etc.)
• Gas (Natural Gas, Coke Oven Gas, Blast Furnace Gas etc.)
Steam Cycle • Ultra-supercritical
• Supercritical
• Subcritical
• Supercritical
• Subcritical
Size (MWe) • Subcritical ≤ 800
• USC/SC ≤ 1,350
• Subcritical ≤ 800
• SC ≤ 1,000
Superheater Outlet Steam Pressure (bar) • ≤ 300 • ≤ 250
Superheater Steam Temperature (°C) • ≤ 605 • ≤ 565
Reheater Steam Temperature (°C) • ≤ 623 • ≤ 565
Design Features • Tangential firing system
• Fuel and air staging
• Tilting burners
• Vertical and spiral wall designs
• Tangential firing system
• Fuel and air staging
• Tilting burners
• Spiral wall designs
TWO-PASS BOILERSFurnace and Convective Passes, Tilting Tangential Firing System, Experience Firing Fuels from All Over the Globe
GE’s two-pass boiler is the workhorse of the power industry, generating steam for today’s large-scale
global power projects (up to 1,350 MWe) at pressures and temperatures that can reach the service limits
of contemporary materials. Radiant pendant surfaces are located above the furnace, and convective
surfaces are arranged horizontally in the second pass. The two-pass configuration results in an
efficient furnace height and a lower cost of construction. Our patented tilting tangential firing system
accommodates the large spectrum of fuels found across the globe (multiple grades of coal, oil, gas, heavy
residues, biomass and other opportunity fuels), and is a leader in primary emissions control.
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Coal-fired Two Pass Oil and Gas-fired Two Pass
STEAM POWER SYSTEMS PRODUCT CATALOG I Boilers
Flexible and Reliable• High cycle efficiencies at ultra-supercritical
conditions reaching 44 to 47 percent on an LHV basis (42 to 45 percent HHV basis), meaning less fuel consumption and cleaner operation
• Low primary NOx emissions using advanced tangential firing systems and effective overfire air arrangements, resulting in less SCR catalyst material and less reagent consumption
• Outstanding operational flexibility for temperature control, grid code requirements, sliding pressure capability, and load cycling
• Reduced construction time and cost using advanced construction techniques and standard component design and fabrication
Powering the World
Powering the World
GE originally introduced the tower boiler design in the mid-20th century to utilize high moisture lignite in Europe. Since then, thanks to its advantages – and positive feedback from customers – the tower boiler has become the predominant design for coal-fired power generation in Europe, according to the EN Codes & Standards. With standardization and modularization, tower boiler equipment can be sourced and constructed cost-effectively around the globe while meeting high quality standards.
Flexible and Reliable• High cycle efficiencies at ultra-supercritical conditions reaching 44 to 47 percent on an LHV basis
(42 to 45 percent HHV basis), meaning less fuel consumption and reduced emissions
• High steam parameters with successful utilization of T24 material
• Low primary NOx emissions using advanced tangential firing systems and effective overfire air arrangements, resulting in less SCR catalyst material and less reagent consumption
• Outstanding operational flexibility to support a stable grid
• Reliable plant operation enhanced by fully drainable heating surfaces, resulting in faster startup periods and reduced stresses in pressure part
Expertise in High Moisture Lignite Firing
TOWER BOILERSSimple and Reliable Design, Expertise for High Moisture Lignite Firing
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Hard Coal Fired Tower Lignite Fired Tower
Fuel • Bituminous
• Sub-bituminous
• Lignite A
• Lignite B
Steam Cycle • Ultra Supercritical
• Supercritical
• Subcritical
• Ultra-supercritical
• Supercritical
• Subcritical
Size (MWe) • Subcritical ≤ 800
• USC/SC ≤ 1350
• Subcritical ≤ 800
• USC/SC ≤ 1,100
Superheater Outlet Steam Pressure (bar)
• ≤ 300 • ≤ 300
Superheater Steam Temperature (°C) • ≤ 605 • ≤ 605
Reheater Steam Temperature (°C) • ≤ 623 • ≤ 613
Design Features • Tangential firing system
• Fuel and air staging
• Tilting burners
• Spiral wall designs
• Tangential firing system
• Fuel and air staging
• Spiral wall designs
• Expert firing system for lignites
Hard Coal Fired Tower Lignite Fired Tower
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STEAM POWER SYSTEMS PRODUCT CATALOG I Boilers
Furnace gas resuction ducts
Beater wheel mills
Mills arranged around furnace Large furnace
• Specialized firing system to burn all types of
lignite with over 80 years of experience
• Integrated with advanced beater wheel mill
providing efficient operation and maintenance
During the past two decades, circulating fluidized bed (CFB) technology has demonstrated its ability to efficiently utilize a wide variety of fuels – including fuels with high ash, high moisture, high sulfur, low volatiles, and low heating value that are unsuitable for other firing systems – while meeting stringent stack emission limits. This unique combination of fuel flexibility and low emissions has led to the development and growth of CFB technology in power generation.
• Efficient Combustion
A wide range of fuels can be burned efficiently, including low-grade and difficult-to-burn fuels such
as anthracite, lignite, petroleum coke, oil shale, discarded coal and biomass.
• Fuel Flexibility
Several different fuels can be fired in the same boiler within a wide range of mixing rates.
• Low inherent NOx emissions at 50-200 mg/Nm3
— Relatively low and uniform furnace temperatures of approximately 850°C to 900°C
— Air staging in the lower furnace through the introduction of primary air and secondary
air at appropriate levels
— Uniformly distributed fuel and air due to intense mixing inside the bed of solids in the furnace
— Isothermal conditions in the circulating solid loop due to the positive impact of
highly efficient cyclones
— Selective non-catalytic reduction (SNCR) systems can be added, leading to even lower
NOx emissions
• Low SO2 emissions with 95 to 98 percent sulfur removal
— Injection of prepared and dried limestone in the furnace
— Potentially inherent capture by the fuel-bound calcium
— Dry scrubber NID* achieving 98 percent sulfur removal while reducing limestone consumption
— Just-In-Time (JIT*) system for limestone drying and crushing available for direct limestone feeding
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STEAM POWER SYSTEMS PRODUCT CATALOG I Boilers
CFB BOILERSCombination of Fuel Flexibility and Low Emissions
Dual-Grate Arrangement Design for specific requirements
Three-Bay ArrangementMost common CFB design
Advanced Supercritical CFBLarge-sized CFB firing system
Fuel Entire range of fuels, including opportunity fuels such as petroleum coke, biomass, waste coal, oil shale, etc.
Steam Cycle • Subcritical • Subcritical • Ultra Supercritical
• Supercritical
Size (MWe) • 350 • 100 – 350 • 660 for lignite B
• Higher for hard coal
Superheater Outlet Steam Pressure (bar)
• ≤ 175 • ≤ 175 • ≤ 285
Superheater Steam Temperature (°C)
• ≤ 565 • ≤ 565 • ≤ 605
Reheater Steam Temperature (°C)
• ≤ 565 • ≤ 565 • ≤ 623
Design Features • Four cyclones • Double grates• External beds
• Up to three cyclones in line • Single grate• In-furnace panels• Steam cooled cyclones
• Modular concept• Standardized modules • Up to 8 cyclones• Steam cooled cyclones• Double fluidizing grates• External beds• In-furnace box columns • In-furnace U-shaped panels
• CFB/NID integrated technology • SNCR in-house injection grid • JIT limestone feed system
Powering the World
Dual-Grate Arrangement Three-Bay Arrangement Advanced Supercritical CFB
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32 33
For nearly 100 years – ever since pulverized coal combustion was adapted for power generation – GE
has been a leader in coal mill technology for the power industry. That leadership continues today
with the world’s largest fleet of installed power milling equipment. Licenses for our milling technology
can be found in all coal-powered regions of the world.
Pulverizing solid fuel to powder enables its drying and transport for combustion in large furnace sizes.
Fine grinding increases the fuel exposed surface area while simultaneously drying and controlling
its distribution. These are integral steps to efficient, low emissions combustion which are optimized
together with boiler thermal performance.
We design and continuously develop a complete range of milling technology that includes vertical
spindle bowl mills and beater wheel mills, with classifier options to match our customers’ efficiency
and fuel flexibility demands. Our mill and classifier portfolio can process all fuels commonly used for
power generation and fuel blends, while maintaining excellent combustion efficiency under low-
emission conditions with reduced power consumption and maintenance requirements.
Bowl Mills – HP Type Bowl Mills – SM Type Beater Wheel Mills – Type S, V, SV
Capacity Range (t/h)
• 18 to 170 • 12 to 170 • 44 to 170 (diam. ≤ 4.4m)
Classifier • Static or dynamic • Static, dynamic and combined • Box type (static)
Loading • Spring (hydraulic option) • Hydraulic (spring option) • Speed control for operational flexibility
Coal • Bituminous/sub-bituminous • Lignite A
• Bituminous/sub-bituminous • Lignite A • Anthracite• Petroleum coke
• Various types of lignite with moisture from 25 to 70 percent and ash content up to 35 percent
Design Features
• Interchangeable components• Removable gearbox• External spring loading• Tilt-out journals • Simple fabricated design • Adaptable arrangements• Extended life moving parts
• Interchangeable components• Removable gearbox• External spring loading• Tilt-out journals • Simple fabricated design • Adaptable arrangements• Extended life moving parts
• Optimized performance designs • Modular heavy duty design• Unique maintenance concept• Easy access to wear parts• Pre-beater design available• Insensitive to sudden load changes • Compliance with European
standards
STEAM POWER SYSTEMS PRODUCT CATALOG I Boilers
MILLSComplete Range of Technology to Meet Low Emission, High Efficiency and Fuel Flexibility Demands
• Demonstrated reliable operation
• Wide fuel range capability, with the ability to handle all solid
fuels suitable for power generation, from anthracite to lignite B
• Enhanced operational flexibility, handling fuel blends, transient
operation, and load ramping, while supporting emissions
compliance
• Reduced capital, labor, maintenance, and operating costs:
— Simple modular design that keeps capital and construction
costs low
— Interchangeable modular components that reduce inventory
costs and repair cycle time
— Unique construction concepts that allow mill installation
without welding for reduced labor costs
Powering the World
Bowl Mills – HP type
Bowl Mills – SM type
Beater Wheel Mills – Type S, V, SV
STEAM POWER SYSTEMS PRODUCT CATALOG I Steam Turbines
STEAM TURBINESPortfolio and Overview
Power and PerformanceA world leader in the development and application of steam turbine technology, GE has supplied more
than 30 percent of the world’s installed steam turbine capacity, totaling more than 930 GW of power
production capability to date in operation. For more than a century, we have consolidated the best
available technology from numerous suppliers into a single platform that supports our advanced,
innovative, efficient and reliable turbine solutions.
GE’s steam turbine platform offers a broad product portfolio that accommodates a wide range of site
conditions, operational needs, advanced steam cycles, and applications. In fossil-fired steam plants,
our steam turbines offer class-leading ultra-supercritical steam parameters.
Experienced and AvailableA systematic evolutionary platform approach that incorporates best practices and technology gains
based on years of practical experience forms the backbone of GE’s coordinated product portfolio.
Our highly qualified and specialized engineering centers and factories – in key marketplaces around
the world – enable us to provide this exceptional portfolio of steam turbine products.
Advanced TechnologyIncreased Efficiency• Continuous improvements to the water steam cycle
are supported by our broad rear stage portfolio.
• Our advanced 3D blading platform helps enhance the load grade and customize the flow path for project-specific conditions and increased performance.
Evolutionary Platform Approach• The application of proven design principles to all module
types and sizes helps achieve higher reliability.
• Operational feedback is systematically applied across GE’s entire modular turbine product portfolio to enhance customer value.
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Products
35
High Availability and Reliability• Advanced lifetime assessment procedures reduce
maintenance and increase turbine availability.
• Our long-term testing program validates material behavior to help ensure high reliability of our steam turbine components.
Enhanced Operational Flexibility• Advanced fracture mechanic methods provide reliable
lifetime assessment of the steam turbine components and increased cycling capabilities.
• An enhanced blade groove design reduces thermal stresses for increased rotor life.
GE ST-D250
GE ST-A200
GE ST-D850
GE ST-A650
GE ST-D650
100 200 300 400 500 600 700 800 900 1000 1100 1200
GE ST-D1050REHEAT Up to 300bar (4351psi)Up to 600°C (1112°F)
REHEATUp to 245bar (3553psi)Up to 585°C (1085°F)
REHEATUp to 190bar (2756psi)Up to 565°C (1049°F)
REHEATUp to 190bar (2756psi)Up to 565°C (1049°F)
NON-REHEATUp to 140bar (2031psi)Up to 565°C (1049°F)
NON-REHEATUp to 140bar (2031psi)Up to 565°C (1049°F)
Up to54.0.%ST efficiency
Up to49.0%ST efficiency
Up to47.5%ST efficiency
Up to47.5%ST efficiency
Up to40.5%ST efficiency
Up to40.5%ST efficiency
Powering the World
Key Technical Features
36 37
STEAM POWER SYSTEMS PRODUCT CATALOG I Steam Turbines
STEAM TURBINESPortfolio and Overview
Welded RotorsIntroduced in 1930, our welded rotor technology has stood the test of time with no ruptures reported in our large diameter rotors – manufactured by welding together separate smaller forgings. This beneficial design allows for:
• Appropriate forging material selection, based on temperature level at each section of the turbine
• Stress reduction during thermal transients for faster and more frequent load cycling capability
• Better access for ultra-sonic testing equipment – translating to higher reliability
Shrink Ring DesignOur shrink ring design allows for a rotationally symmetric inner casing resulting in:
• Reduced distortions while clearances are maintained during operation – providing sustained higher efficiency
• A more compact design with smaller wall thicknesses for flexible load cycling and faster startup times
Single Bearing DesignOur multi-casing turbines have a single bearing between each turbine section for:
• Avoidance of load shifting for higher reliability
• Efficient shaft alignment for reduced construction time
• Shorter overall turbine shaft length for lower building costs
LP Large Last Stage BladesOur enhanced last stage blade portfolio offers:
• Dense staggered last stage blade sizes for project-specific cold-end conditions and increased efficiency
• A robust design with stress-enhanced grooves and blade attachments for higher reliability
Advanced BladingInnovative blading technology is apparent in our:
• Modern, three-dimensional profile design that results in higher efficiency
• High pressure (HP), intermediate pressure (IP), and low pressure (LP) front stage blades that are milled from a single forging for excellent mechanical integrity and higher reliability
Blade size for 50 Hz and 60 Hz
50 Hz/60 Hz 33” (50 Hz) 33” (50 Hz) 37”/30” 41”/34” 41”/34” 45”/38” 49”/42”
Design Free-standing Snubber Free-standing Snubber and Shroud
Material Steel Titanium
Powering the World
D1050, D850, D650, AND A650 STEAM TURBINESModular Steam Turbine Platform for High Efficiency
GE’s D-Series is a modular product platform for utility reheat steam turbines in the 100 to 1,200 MW
power output range. Our modular concept governs all engineering and manufacturing processes, and
results in reduced construction and commissioning times, higher reliability, and excellent efficiency.
To enhance performance, the steam path is always adapted to the specific project requirements.
The extensive LP last stage blade portfolio for 50 Hz and 60 Hz models offers rear stage sizes from
30 inches up to 49 inches. The number and size of LP turbines can be tailored to specific site conditions.
The D1050 steam turbine configuration can have up to five casings.
D1050: 400-1200 MW output
Up to 54 percent steam turbine efficiency
D850: 200-1000 MW output
Up to 49 percent steam turbine efficiency
38 39
STEAM POWER SYSTEMS PRODUCT CATALOG I Steam Turbines
Designed for Efficiency and Reliability• The D-Series are designed for main inlet conditions up
to 600°C (1112°F) and 300 bar (4351 psi) and reheat temperatures up to 620°C (1148°F).
• HP turbines can be equipped with a second main steam injection system by means of integrated overload valves. This method provides additional load reserve in cases of sudden steps in power demand.
• Startup valves (TAL) help ensure a safe and trip-free runback from full load to house load after load rejection.
• HP, IP, and valve units are shipped fully assembled enabling shorter installation time on site. The LP turbine is dispatched in pre-assembled lots for easier handling and reduced construction time on site.
• Skid mounted lube and control oil systems with pre-assembled pumps, filters, valves, and interconnecting piping are available for all turbine sizes.
• Sleeved rotor couplings help ensure durable shaft alignment and smoother operation.
D650: 200-700 MW output
Up to 47.5 percent steam turbine efficiency
Powering the World
40 41
Technical DataD1050 D850 D650 A650
Main SteamUp to 300bar (4351psi)Up to 600°C (1112°F)
Up to 245bar (3553psi)Up to 585°C (1085°F)
Up to 190bar (2756psi)Up to 565°C (1049°F)
Up to 190bar (2756psi)Up to 565°C (1049°F)
Reheat Temperature
Up to 620°C (1148°F) Up to 585°C (1085°F) Up to 565°C (1049°F) Up to 565°C (1049°F)
Frequency 50 Hz and 60 Hz 50 Hz and 60 Hz 50 Hz and 60 Hz 50 Hz and 60 Hz
Output ≤ 1200 MW ≤ 1000 MW ≤ 700 MW ≤ 300 MW
Steam Turbine Efficiency
Up to 54% Up to 49% Up to 47.5% Up to 47.5%
Maximum Backpressure
0.35 bar (10.34 inHg)(0.7 bar (20.67 inHg) with special high back pressure rear stages)
Control ConceptSliding pressure modeHybrid mode with or without overload valve
Sliding pressure modeFixed pressure mode
STEAM POWER SYSTEMS PRODUCT CATALOG I Steam Turbines Powering the World
D1050, D850, D650, AND A650 STEAM TURBINESModular Steam Turbine Platform for High Efficiency
D250 STEAM TURBINEPlatform with Enhanced Design Flexibility
Decades of experience have shaped GE’s D250 platform into an innovative selection of pre-engineered
sections and modules that offer flexibility. Available with downward exhaust options, the D250
platform can be integrated into any plant configuration.
With its full modular design, the D250 platform can be tailored to meet our customers’ specific
project requirements in a double casing arrangement. Turbines with a rear stage size up to 41 inches are
completely shop assembled and shipped directly to the site to reduce construction time.
The reuse of standard sections and the consequent application of an experience return process supports
continuous product design improvements and results in the high reliability of the D250 platform.
4342
STEAM POWER SYSTEMS PRODUCT CATALOG I Steam Turbines
Versatile and Robust Design• The D250 platform is designed for main steam inlet
conditions up to 565°C (1049°F) and 140 bar (2031 psi).
• A single or reverse flow steam path controls axial thrust and axial thermal expansion to help ensure high reliability.
• Double flow LP turbines meet project specific back pressure requirements.
• Flexible heat extractions can be arranged along the steam path to extract the steam at exactly the pressure that is needed.
D250 Platform Technical Data
Main Steam 140 bar (2031 psi), 565°C (1049°F)
Frequency 50 Hz and 60 Hz
Output ≤ 300 MW
Steam Turbine Efficiency Up to 40.5%
Maximum Backpressure0.35 bar (10.34 inHg) (0.7 bar (20.67 inHg) with special high back pressure rear stages)
Control ConceptSliding pressure modeFixed pressure mode (control stage)Hybrid mode
Powering the World
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A200 STEAM TURBINEMultiple Steam Extractions, Flexible Arrangement Concept
GE’s A200 non-reheat steam turbines provide cogeneration of power steam in an flexible and compact
design for either 50 Hz or 60 Hz application. Our fully modular concept combines HP, IP, and LP sections
to deliver high efficiency and process steam supply.
Available with a single casing, A200 steam turbines have internally and externally controlled flow
extractions to tap steam at any point along the steam path at the desired flow and pressure
conditions. Arrangement options are available with axial exhausts.
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STEAM POWER SYSTEMS PRODUCT CATALOG I Steam Turbines
Compact and Flexible• The A200 turbine is designed for main steam inlet
conditions up to 565°C (1049°F) and 140 bar (2031 psi).
• For added flexibility, the A200 steam turbine is available as a single casing solution with a single flow LP section or as double casing solution with a two-flow LP section.
• Turbine cylinders are shipped fully assembled to reduce site work and construction time.
• An extensive LP blades portfolio allows a customized rear stage selection to fit all ambient conditions and achieve higher efficiency steam cycles.
• A flexible arrangement of steam extraction nozzles along the blade path helps extract steam for project-specific conditions.
• Design solutions for internally controlled steam extractions are available. Adaptive stage technology is used to control low pressure steam extractions, while intersections with dedicated valves are appropriate for higher pressures.
A200 Turbine Technical Data
Main Steam 140 bar (2031 psi), 565°C (1049°F)
Frequency 50 Hz and 60 Hz
Output ≤ 300 MW
Steam Turbine Efficiency Up to 40.5%
Maximum Backpressure0.35 bar (10.34 inHg) (0.7 bar (20.67 inHg) with special high back pressure rear stages)
Control ConceptSliding pressure modeFixed pressure mode (control stage)Hybrid mode
Powering the World
STEAM POWER SYSTEMS PRODUCT CATALOG I Generators
GENERATORPortfolio and Overview
GE’s generators are experienced and reliable machines that offer high technical performances. Our
generators have successfully operated in more than 2,000 projects worldwide, providing different
power output levels and cooling media depending on customer need. Designed to help lower plant
investment costs, our generators enhance operation and limit maintenance costs.
Product Families• GIGATOP 2-pole (hydrogen-water-cooled) generators are GE’s enhanced solution for coal power plant
applications. This generator has operated in more than 100 projects since 1973. A power plant in the
Netherlands has the world’s most powerful generator (1,113 MW) running in a coal power plant.
• TOPGAS (hydrogen-cooled) generators are high-efficiency machines. The high power output of this
product family provides a cost-effective alternative to conventional hydrogen-water-cooled machines
that are commonly used for similar high power output levels.
• TOPAIR (air-cooled) generators are precise and robust machines offering high power output
and efficiency. This machine can be used in many different applications.
• TOPACK (air-cooled) generators are ideal for applications demanding simple, packaged and
ready-to-install generators. There are more than 1,500 machines installed worldwide.
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Product Power Output Range (MW)
510–1,400 MW
400–830 MW
GIGATOP 2-poleHydrogen-water-cooled
TOPGASHydrogen-cooled
70–430 MWTOPAIRAir-cooled
30–170 MWTOPACKAir-cooled
Technologies Bring Added ValueGE’s generators use technologies and contain features that save time and money for the end customer.
Based on many years of proven experience and continuous feedback from our customers, these
technologies often are shared among different product families, as shown in the following three examples.
Tubes in Stainless Steel for Stator-Winding Cooling
Used on GIGATOP 2-pole generator
• The cooling tubes in the stator winding of GE’s GIGATOP 2-pole generator are made of
stainless steel, so they can’t corrode, and the risk of clogging leading to an unplanned
forced outage is eliminated. GE is the only manufacturer to offer this feature.
Self-Retightening End-Winding Support
Used on TOPAIR, TOPGAS and GIGATOP 2-pole generators
• GE’s generators have a self-retightening end-winding support, which allows thermal
expansion of the bars while simultaneously tightening the winding in radial and
tangential directions. This system saves maintenance time for the generator end
user, avoids forced outages, and increases plant availability on the grid.
Concave-Convex Wedges
Used on TOPAIR, TOPGAS and GIGATOP 2-pole generators
• The concave-convex wedges used in GE’s generators have a unique design that
sustains pressure on the stator bars. This constant pressure prevents radial
movements of the winding, avoiding a forced outage from insulation breakdown
while cutting maintenance hours and increasing plant availability.
47
GE’s generators are designed to meet all relevant standards, regulations and grid codes that may apply
in specific 50 Hz and 60 Hz countries. Machines are designed according to IEC and IEEE standards and
are designed for temperature rises of class 130 (B). The insulation, using either DURITENAX or MICADUR*
tape (depending on the product family), fulfills thermal class 155 (F). We perform quality tests and
inspections during manufacturing, delivery, construction and commissioning of the machines to help
ensure high quality and conformance with our customers’ needs.
Powering the World
GE’s generators have additional design features that enhance technical performance and reduce
maintenance costs:
• Roebel bars in the stator winding reduce losses and heighten efficiency.
• The MICADUR* insulation system is a well-proven insulation tape that helps ensure
high reliability.
• Laminated press-plates and low-loss core laminations enhance efficiency.
The following table summarizes the availability of features within each product family.
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STEAM POWER SYSTEMS PRODUCT CATALOG I Generators
GENERATOR Portfolio and Overview
GIGATOP 2-pole TOPGAS TOPAIR TOPACK
Stator end-winding support for short maintenance time P P P P
Enhanced stator bars insulation for reliable operation
MICADURVPI
MICADURVPI
MICADURVPI
DURITENAXResin Rich
Concave-convex wedges for reliability and short maintenance time
P P P Ripple Spring System
Enhanced stator core design for low losses and maintenance P P P P
Enhanced seal oil system for low hydrogen losses and high efficiency
Triple-circuit Seal Oil System
Single-circuit Seal Oil System — —
Enhanced cooling system for high efficiency Hydrogen and water Hydrogen Air Air
Skid-mounted auxiliaries that save time on site P P — —
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Powering the World
Success Story
GIGATOP 2-POLE GENERATORReliable Hydrogen-Cooled Generator
High-tech Features for Best PerformanceThe hydrogen- and water-cooled GIGATOP 2-pole generator is used for coal power plants, nuclear full-
speed turbines, and gas power plants and can be found in 100 systems since 1973. Flexible in design,
each machine fits the end user’s power needs with high efficiency. The GIGATOP 2-pole generator has
proven to be highly reliable. For example, a unit in the U.S. boasted 607 days of uninterrupted
operation before a scheduled shutdown.
Based on technology pioneered in the 1970s, the GIGATOP 2-pole generator is constantly improved
with continuous feedback from operational experience worldwide. Designed for both rail and road
transport, the generator has only a small number of individual parts, which translates into
shorter delivery and faster installation time.
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STEAM POWER SYSTEMS PRODUCT CATALOG I Generators
Features:• High power output levels. For example, the GIGATOP
2-pole generator in the operation in Leibstadt (Switzerland) nuclear plant at 1,190 MW.
• Efficient and flexible. The cooling system sustains a high level of efficiency and has a unique design of press plates for higher reactive power and stabilization in case of grid disturbance.
• Robust and reliable design. The design takes into account normal operation and transcients.
• Continuously evolving technology. The first GIGATOP 2-pole generator was developed in the 1970s and has evolved continuously ever since, based on feedback collected from operating experience.
Applications:• GIGATOP 2-pole generator is well-suited for the
nuclear full-speed Turbine Generator package.
• GIGATOP 2-pole generator represents more than 100 units installed, and its design combines high efficiency, high reliability and optimized maintenance efforts for the benefit of our customers.
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1 Average reliability calculated according to standard IEEE-762 from measurements collected over nine GIGATOP 2-pole units between 1990 and 2012 by the independent company Strategic Power System
Frequency 50 Hz 60 Hz
Power Factor 0.8 to 0.9 0.85
Apparent Power 590 MVA to 1400 MVA 510 MVA to 1120 MVA
Efficiency Up to 99% Up to 98.9%
Terminal Voltage 18 kV to 27 kV 22 kV to 26 kV
Reliability1 99.996%
First 1,000 MW Coal Plant in China from GE Since the rail network in China has narrow tunnel profiles and load restrictions, a specific GIGATOP 2-pole generator was designed to fulfill all of China’s specific technical and rail transportation requirements for dimensions and weight.
Powering the World
Success Story
TOPGAS GENERATORBest-in-Class Hydrogen-Cooled Generator
TOPGAS hydrogen-cooled generators benefit from a strong heritage of technology and extensive
operational feedback. The TOPGAS power output range is a cost-effective alternative to bigger and
more complex hydrogen-water-cooled generators.
Today’s TOPGAS generator power output range goes beyond 710 MVA (ca. 600 MW), so the generator
can be installed in power plants that generally would require more complex hydrogen-water-cooled
generators, such as conventional 660 MW coal power plants. By offering a lower investment cost and
higher efficiency than conventional hydrogen-water-cooled generators, the TOPGAS generator reduces
electricity costs and emissions.
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STEAM POWER SYSTEMS PRODUCT CATALOG I Generators
Features• Lower investment cost, derived from the high power
rating and the generator’s efficiency. TOPGAS machines are a cost-effective alternative to more complex hydrogen-water-cooled generators that normally are used for similar power output levels
• Excellent 99.7 percent reliability, based on measurements collected from 34 TOPGAS units between 1998 and 2012
• High efficiency of around 99 percent, mainly because of the enhanced winding and hydrogen cooling system
• Easy to maintain, thanks to specific design features of the stator bar wedging and stator end-winding support parts
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1 Average reliability calculated according to Standard IEEE-762 from measurements collected from 34 TOPGAS units between 1998 and 2012 by the independent company Strategic Power System.
TOPGAS in High Cyclic Operation A TOPGAS unit in a 400 MW gas-fired combined cycle plant, powering a Japanese steel production facility, has been operating reliably in daily start-stop mode since September 2002, accumulating more than 2,050 starts and more than 48,000 operating hours.
Frequency 50 Hz 60 Hz
Power Factor 0.8 0.85
Apparent Power 400 MVA to 830 MVA 450 MVA to 615 MVA
Efficiency Up to 98.9% Up to 99%
Terminal Voltage 18 kV to 23 kV 19 kV to 23 kV
Reliability1 99.715%
Powering the World
Success Story
TOPAIR GENERATORPrecise and Robust Air-Cooled Generator
The most powerful air-cooled generator in operation today, GE’s TOPAIR unit has accumulated worldwide operational experience from more than 570 installations. It is a robust machine providing high reliability and maintainability.
TOPAIR air-cooled generators have a power output range that usually is found in larger and less cost-effective hydrogen-cooled generators. This is the result of continuous, evolutionary development that has pushed the limits of power output while enhancing efficiency and controlling investment costs. At the same time, it is simple and easy to operate and maintain.
The flexible TOPAIR, because of its short production time (parallel manufacture of stator and casing, pre-assembly, and ease of transport), is a generator that can be up and running quickly. This reduces construction and commissioning time and accelerates plant revenue flow.
TOPAIR units are available in standardized sizes, with different capabilities and performances.
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STEAM POWER SYSTEMS PRODUCT CATALOG I Generators
Features• Cost advantage due to high power rating and efficiency,
over hydrogen-cooled generators
• Continuous improvement from the latest advanced technology, including enhanced power range and efficiency at limited product cost
• Proven operational flexibility from demonstrated robustness and reliability over many years in all operation modes
• Extensive worldwide operational experience with more than 570 units installed worldwide
55
1 Average reliability calculated according to Standard IEEE-762 from measurements collected from 304 TOPAIR units between 1990 and 2012 by the independent company Strategic Power System.
TOPAIR Working in a Tough Environment More than 200 TOPAIR generators have been installed in the Middle East, where their durability and robustness are tested to the limit by extreme operating conditions. For example, 32 TOPAIR units have been operating in Saudi Arabia since 1978. Bahrain is host to the world’s largest air-cooled generator, which has been operating since 1999 and has accumulated more than a million operating hours.
Frequency 50 Hz 60 Hz
Power Factor 0.8 0.85
Apparent Power 70 MVA to 430 MVA 80 MVA to 360 MVA
Efficiency Up to 98.9% Up to 98.8%
Terminal Voltage 11.5 kV to 22 kV 13.8 kV to 22 kV
Reliability1 99.911%
Powering the World
Success Story
TOPACK GENERATORPackaged Air-Cooled Generator
The air-cooled TOPACK generator is remarkable for its breadth of customer advantages and its accumulated experience.
The packaged TOPACK solution comes complete with all necessary electrical equipment, saving our customers time, effort and money. Compact and modular, based on standardized manufacturing processes, a TOPACK generator quickly gives our customers exactly what they need. It is delivered as a single unit that is ready to install, simple to integrate into the power plant, and easy to maintain.
The TOPACK generator is highly reliable, with a wide power range that is versatile enough to handle all kinds of applications – indoor or outdoor and in a variety of climates.
TOPACK generators are available in standardized sizes, with different capabilities and performances.
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STEAM POWER SYSTEMS PRODUCT CATALOG I Generators
Features• Fully packaged generator that comes complete
with all electrical systems
• Reliable and robust product, with more than 1,300 installations worldwide and proven in many different environments
• Compact size and easy maintenance for quick and easy transportation and installation
57
Extreme Operating Conditions A refinery in Kazakhstan is located at one of the largest oil field in the world and faces extreme ambient temperatures reaching -36°C. Two TOPACK units are installed there to produce electrical power and these machines have operated reliably for more than 10 years.
Frequency 50 Hz 60 Hz
Power Factor 0.8 0.85
Apparent Power 35 MVA to 200 MVA 35 MVA to 200 MVA
Efficiency Up to 98.7% Up to 98.6%
Terminal Voltage 11 kV to 15 kV 13.8 kV
Powering the World
North AmericaPower 160 GWIndustry 360 Systems
Latin AmericaPower 7 GWIndustry 230 Systems
EuropePower 113 GWIndustry 1,600 Systems
Middle East and AfricaPower 40 GWIndustry 160 Systems
Russia and CISPower 13 GWIndustry 80 Systems
AsiaPower 98 GWIndustry 1,800 Systems
IndiaPower 50 GWIndustry 700 Systems
OceaniaPower 20 GWIndustry 120 Systems
STEAM POWER SYSTEMS PRODUCT CATALOG I Air Quality Control Systems
AIR QUALITY CONTROL SYSTEMS (AQCS)Portfolio and Overview
Pioneer in Air Quality Control for Power and Industrial ApplicationsWe have provided our customers with advanced Air Quality Control Systems (AQCS) for more than
80 years. GE’s expertise, technology and comprehensive product portfolio enable our customers to
comply with today’s stringent emission regulations for particulate and gaseous pollutants emitted
from power plants and industrial operations. Our high quality and cost-effective equipment and services
can be adapted to our customers’ needs.
58 59
Our Success:
500 GWIn Power Applications
5,000Units in Industrial Applications
More than 80 years of experience providing advanced emission controlsAt GE, we:• Help our customers determine the best combination of technologies for their
specific site requirements
• Offer a range of products to comply with today’s stringent emissions regulations
• Deliver a variety of AQCS on an engineering, procurement and construction (EPC) or engineering and procurement (EP) basis
• Provide after-sales services including spare parts, inspection and remote monitoring
• Offer a variety of solutions to upgrade our customers’ existing equipment with our latest innovations for improved performance and/or lower operating costs
Powering the World
STEAM POWER SYSTEMS PRODUCT CATALOG I Air Quality Control Systems
AIR QUALITY CONTROL SYSTEMS (AQCS)Portfolio and Overview
60 61
Customized OfferingsWith GE, customers receive a wealth of air quality control know-how. For new built
and upgrade and retrofit of existing AQCS, we offer on-demand solutions tailored to
meet our customers’ requirements, including partial or full scope as described below:
• Engineering. GE offers advanced air pollution control engineering, from process
and equipment design to construction, operations and maintenance.
• Equipment supply. Our comprehensive AQCS portfolio of products covers a
broad range of pollutants with industry leading technology with a single process or
a combination to cover the entire flue gas chain. This gives customers the flexibility
to address complex interactions between components and processes.
• Construction and commissioning. We offers:
— Construction management
— Commissioning management
— Construction and commissioning advisory services
• Inspection and maintenance. We provide these services for
our own fleet and/or other AQCS solutions.
Innovative Products and TechnologiesSince 1983, our technology center in Växjö, Sweden – one of the largest in the world in the field of
environmental control solutions – has been at the forefront of advanced research and development for
air quality and CO2 control solutions. Focusing on technology innovation and product validation, it has
test halls for pilot operations and flow modeling, an analytical laboratory specializing in particle and
environmental analyses, an instrument workshop, high voltage facilities for ESP electrical testing (SIR,
T/R sets), and a mechanical workshop for pilot equipment manufacturing.
Powering the World
Success Story
Electrostatic precipitators (ESPs) represent a very large installed base worldwide in terms of particulate
emission control, and GE offers a wide range of robust, cost effective and reliable ESP designs for a variety
of applications. Backed by decades of experience on an extended range of fuel combinations and industrial
applications, our solutions cater to increasingly strict regulations at a lower life cycle cost. We offer:
• Spiral and rigid designs of emitting electrodes, tumbling hammer and electric impact
rapping systems
• Flexible layout and modular designs suited to the site
• Integrated ESP control systems, including the latest generation EPIC intelligent controller and the
ProMo tool for enhanced ESP performance
• Switch Integrated Rectifiers (SIR) as an alternative to Transformer/Rectifier (T/R) sets for increased
power input, lower power consumption and improved particulate removal efficiency. Ideal for
performance enhancement of existing ESPs.
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1 Industry- Cement: Kiln, Mills, Cooler; Iron & Steel: Sintering, Pelletization, Sponge Iron Kiln, Cast House, Stock House; Biomass fired boilers; Waste to Energy plants; Pulp & Paper: Recovery Boiler, Lime Kiln; Non-Ferrous- Smelter, Converter; Oil & Gas: FCCU et. al.
2 Industry - Iron & Steel- Blast Furnace, Iron & Steel- Scarfing, Iron & Steel- Converters, Aluminium- Anode Baking
GE has installed seven ESPs in Europe’s largest power station based in Poland. Six of the units are of 370 MW capacities and the latest unit is of 858 MW capacity, all firing lignite fuel. The six ESPs of 370 MW are designed with multiple electrode spacing (400 mm and 500 mm) in the front and rear fields – an advanced concept developed by our ESP experts at our R&D center in Vaxjo, Sweden. Multiple spacing helps in saving both capital expenditure and operational costs of the ESPs while maintaining the emission performance. Two of the units were recently commissioned and have successfully achieved emissions of less than 10 mg/Nm3.
STEAM POWER SYSTEMS PRODUCT CATALOG I Air Quality Control Systems
Dry ESPParameter Number
Applications Power-Boilers and Heaters, Industry1
Power Capacity (MW) 10 to 1300
Gas Temperatures (°C) 70 – 400
Gas Flow Rate (m3/s) 15 – 2000
Dust Loading at ESP inlet (g/Nm3) 0.2 – 100 g/Nm3; for SDA 600 g/Nm3; for NID 1800 g/Nm3
Emission at ESP outlet (mg/Nm3) 10 – 200 (exceptional 1000 for ESP as precollector), filterable PM only
PM Removal Efficiency Up to 99.95%
Availability Up to 98%
Wet ESPParameter Number
Applications Power-Boilers, Heaters, Synthesis Gas and Industry2
Gas Temperatures (°C) Up to 70 C , Saturated Gas
Gas Flow Rate (m3/s) 15 – 2000
Dust Loading at ESP inlet (g/Nm3) Up to 1.2
PM Emission at ESP outlet (mg/Nm3) 0.5, filterable PM only
SO3 Emission (ppm) <1 ppm
PM & SO3 removal efficiency 99%
Availability Up to 98%
PARTICULATE CONTROLDry and Wet Electrostatic Precipitators (ESPs)
Key Features of Dry ESP• Proven particulate matter removal for power and
industry applications
• Less than 10 mg/Nm3 emissions
• More than 237 GW installed in power generation and 70-plus years of experience
• Excellent and efficient design with lower cost modular systems
In addition to dry ESP technology, GE also offers horizontal wet ESPs for specific applications such as power, metallurgy, and waste to energy.
Key Features of Wet ESP• Ultra-low particulate emissions (less than 1mg/Nm3), acid mists, aerosols, hazardous air pollutants (HAP)
• More than 80 references for various applications
Powering the World
Success Story
PARTICULATE CONTROL Fabric Filters
Operational and fuel flexibility are increasingly important today, even as air quality regulations are becoming
more stringent. For particulate removal, fabric filters offer a flexible alternative to electrostatic precipitators
(ESPs), particularly when dust characteristics are challenging or variable. GE offers both high ratio (pulse jet)
and low ratio (reverse air) options, depending on the application.
Fabric filters may be used stand-alone or integrated in Dry Flue Gas Desulfurization (DFGD) solutions (NID*
or SDA), for dry scrubbing in the aluminum industry (Abart*), or as the principal and polishing filters in
mercury control solutions (Mer-Cure* or Filsorption*).
64 65
Fabric FiltersParameter Number
Types Pulse jet filters and Reverse air filters
Applications Power – Boilers and Heaters, Industry1
Power Capacity (MW) 10 to 1000
Gas Temperatures (°C) 25 – 260
Gas Flow Rate (m3/s) 10 - 1500
Dust Loading at FF inlet (g/Nm3) 2 – 100; for NID up to 2000
Emission at FF outlet (mg/Nm3) 5 – 50 wet @ operating O2 level (dry filterable particulate only), filterable PM only
Availability (%) Up to 99%
Bag Life Guarantee (Years) 1 to 6 depending on application and filter type
1 Industry- Cement: Kiln, Mills, Cooler; Auxiliary dedusting, Iron & Steel: sintering, pelletization, cast house, stock house, coke oven; Biomass fired boilers; Waste to Energy plants; Pulp & Paper: lime kiln et.al.
STEAM POWER SYSTEMS PRODUCT CATALOG I Air Quality Control Systems
Key Features• Lower than 5 mg/Nm3 particulate emissions possible,
greater than 99.97 percent particulates removal efficiency, high PM10 and PM 2.5 removal rate
• More than 45 GW installed base in power applications
• Filters up to 12 meters tall for reduced footprint and operational costs
• Bag life in excess of five years achieved
• Large fuel flexibility and ability to handle varying boiler loads
• Renowned Optipulse* filtration technology with gravimetric flow and Optipow* plunger valves for efficient bag cleaning
• Stand-alone or integrated in multi-pollutant systems
• Latest EFFIC controller and ProMo software for superior FF performance
• The combination of Optipow valves and EFFIC controller on a new or existing fabric filter provides better bag life compared to other solutions available in the market
Optipulse Mega Fabric Filters After successfully installing and operating electrostatic precipitators on its three initial 700 MW units, a leading power plant in Malaysia decided to apply mega fabric filters with Optipulse technology and 10-meter-long bags for its fourth 1,000 MW unit. The fabric filter was designed to offer low emissions across varying input conditions. The stack emission during the recently conducted PAC of Unit 4 was measured at less than 5 mg/Nm3.
Powering the World
Success Story
66 67
DFGD (NID) Parameter Number
SO2 Removal Rate (%) Up to 98
SO3 Removal Rate (%) Up to 95
HCl Removal Rate (%) Up to 95
HF Removal Rate (%) Up to 95
Maximum SO2 Content at Inlet (mg/Nm3)
10,000
Particulate Emission Guarantee (mg/Nm3)
10
Fuel Applicable for all fuels
Max Inlet Temperature (°C) 200
Load Range per Module (%) 50 - 100
Reagent Ca(OH)2 or CaO
Availability (%) Up to 97
In response to multi-pollutant emissions regulations from the Massachusetts Department of Environmental Protection, a leading energy company in Somerset installed our NID on one of its units. The modular design of the NID allows the plant to operate at 20 percent without flue gas recirculation and with one module out of service, without any impact on boiler operation.
STEAM POWER SYSTEMS PRODUCT CATALOG I Air Quality Control Systems
SOx CONTROL Dry Flue Gas Desulfurization (DFGD)
Dry desulfurization systems have been used for SOx control and multi-pollutant control for several
decades. They are generally based on lime utilization as sorbent, and the end product is dry with no
need for important waste water treatment as compared to wet systems.
GE’s portfolio of dry flue gas desulfurization (DFGD) solutions includes:
NID*
This system is made up of a patented integrated hydrator/mixer, a J-duct reactor and typically a fabric filter.
Hydrated lime is used as a reagent to react with gaseous pollutants like SOx, HCl and HF. Mercury collection
can be realized by injecting PAC upstream. The collected particles are either recirculated or disposed.
Key Features• More than 20 years of successful commercial operation, 15 GW installed for power applications
• Up to 98 percent SO2 removal, up to 4 percent sulfur in coal, multi-pollutant control
• Compact footprint of less than 50 percent, compared to Spray Dryer Absorber (SDA)
• Modular and standard design for lower construction costs and eligible for small projects up to very large power plant size
• Simple operation and maintenance; low operational costs
• A well-fitted technology for various industry applications, in particular waste-to-energy, iron and steel
Spray Dryer Absorber (SDA)
This conventional dry FGD system is made up of a reactor followed by a fabric filter. In the reactor,
the reagent slurry solution is atomized using either GE’s rotary atomizer technology or dual fluid
nozzles, and the droplets react with the gaseous pollutants in the flue gas stream.
Key Features• More than 35 years of experience, 15 GW installed capacity for power
and industry applications
• Up to 95 percent SO2 removal, up to 2.5 percent sulfur in coal
DFGD (SDA) Parameter Number
SO2 Removal Rate (%) Up to 95
SO3 Removal Rate (%) Up to 95
HCl Removal Rate (%) Up to 95
HF Removal Rate (%) Up to 95
Maximum SO2 Content at Inlet (mg/Nm3)
6,000
Particulate Emission Guarantee (mg/Nm3)
10
Fuel Applicable for all fuels
Max Inlet Temperature (°C) 260
Load Range per Module (%) 15 - 100
Reagent Ca(OH)2 or CaO
Availability (%) Up to 98
Powering the World
NID
Success Story
Wet flue gas desulfurization (WFGD) has been the most common technology for SOx control for
more than four decades.
GE’s WFGD portfolio consists of the following options:
WFGD-Open Spray Tower (OST)
The third generation WFD-OST operates over a range of 300 to 1,300 MW. The system offers lower power
consumption and has smaller dimensions compared to previous generations, while reaching nearly zero
emissions. The gypsum by-product recovered is usable as wallboard or cement quality.
GE’s Flowpac WFGD is designed for unit sizes up to 360 MW. In this turbulent bed absorber, flue
gas passes through limestone slurry. It is targeted for applications with fuels having medium to high
sulfur content and requiring increased SO2 and SO3 removal efficiency. In addition, it is well suited for
varying fuel conditions.
Key Features• Approximately 58 GW installed capacity
• Flexible absorber performance with controllability of the SO2 removal rate
• Improved performance control through patented sulfite analyzer
• Fuel flexibility for all types of fuel (including heavy fuel oil) with sulfur content up to 4.5 percent for WFGD-OST and up to 6 percent for Flowpac WFGD
• Lower power consumption with lower emissions of particulates and aerosols
Sea Water FGD (SWFGD) Technology
GE’s SWFGD is a unique no by-product SO2 removal solution. Thanks
to more than 40 years of experience in SWFGD technology for power
generation and industry applications, we are one of the leading
providers of SWFGD for power generation and industry applications.
Key Features• An economical desulfurization solution for plants in coastal areas
• Approximately 51 GW in operation or under construction for a variety of applications and a wide range of fuels
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In 2015, we successfully commissioned our SWFGD solution at a leading coal-fired power plant in Malaysia. It is the first 1,000 MW plant in Malaysia and the single largest unit in Southeast Asia. The SWFGD system lowers SOx emissions over a wide load range, helping the plant meet its environmental responsibilities.
STEAM POWER SYSTEMS PRODUCT CATALOG I Air Quality Control Systems
SOx CONTROLWet Flue Gas Desulfurization (WFGD)
SWFGD Parameter Number
Maximum Gas Flow Rate – per Absorber (Nm3/h)
3,400,000
Power Plant Size (MW) up to 1,000
FuelCoal, lignite, oil, HFO, industrial processes
Maximum SO2 Content at Inlet (mg/Nm3)
15,000
SO2 Removal Rate – with GGH (%)
98
Load Range (% MCR) 20 - 100
Seawater Temperature Inlet to Absorber (°C)
4 - 45
Alkalinity – Minimum (mmol/l) 1.2
pH Seawater Inlet (minimum) 7.7
WFGD-OST Parameter Number
Maximum Gas Flow Rate – per Absorber (Nm3/h)
3,200,000
Power Plant Size (MW) up to 1,300
FuelCoal, lignite, oil, HFO, industrial processes
Maximum SO2 Content at Inlet (mg/Nm3)
17,000
SO2 Removal Rate (%) > 99 achieved
Load Range (% MCR) 20 -100
HCl Removal Rate (%) > 99
HF Removal Rate (%) > 99
ReagentLimestone, lime or sodium
Powering the World
Success Story
GE’s Selective Catalytic Reduction (SCR) technology controls nitrogen oxides (NOx) formed in combustion
processes. With more than 30 years of experience with SCR technology for power generation and industry
applications, GE’s lower cost DeNOx solutions help customers reach their requested performance
levels. High NOx reduction rates and system reliability make our flexible and compact SCR technology
the choice for post combustion NOx control.
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In July 2008, GE’s technology was chosen by the main power producer in Portugal to retrofit four SCR units at a power plant in southern Portugal. These SCR units are designed for 81 percent NOx removal efficiency and use heated ammonia solution as the reagent and a vanadium/titanium honeycomb catalyst.
With these SCR units, Portugal has become one of the few countries in Europe to have equipped all of its coal-fired plants with systems to control both SOx (sulfur oxides) and NOx, thus meeting European Union emission targets.
STEAM POWER SYSTEMS PRODUCT CATALOG I Air Quality Control Systems
SCR Parameter Typical Information
Reactor Size 3,200,000 acfm, 5,400,000 m3/h
Fuel Type Gas, fuel oil, orimulsion, pet coke, biofuel (virgin wood or peat), coal
Reactor Position High dust SCR for power plants and CHP plants; tail end SCR for waste incinerators
Reactor Flow Direction• Coal applications: vertical down• Oil applications: vertical up or vertical down• Gas applications: vertical up or vertical down and horizontal
Cleaning Method Soot blower using steam or compressed air, sonic air horns, air sweepers
NOx Removal Efficiency Up to 95%
NH3 Slip 2 vppvd @ 3% O2
Operation Temperature570-815°F, 300-435°C for coal/oil 450-850°F, 230-435°C for gas
NOx Inlet Concentration 2050 mg/Nm3
O2 1% minimum
SO2 3,500 ppm
SO2/ SO3 Conversion 0.5 - 2.0%
Ash Load 35,000 mg/Nm3
Reagent Type Anhydrous ammonia, aqueous ammonia, urea
NOx CONTROLSelective Catalytic Reduction (SCR)
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Key Features• More than 48 GW installed with more than 80
installations
• Up to 95 percent NOx removal, low ammonia slip (less than 2 ppm)
• Proprietary IsoSwirl* mixing technology and specific ammonia injection grid design for improved performances
• Partnerships with leading catalyst suppliers
• Design tailored to existing site conditions for reduced outage time
Powering the World
SCR on a steam power plant
Success Story
With the knowledge gained from our more than 80 years of experience designing larger sized units,
GE has developed the Smartline range of products to cater to smaller-sized applications such as
district heating, small power units, thermic fluid heaters, lime kilns, foundries, and metallurgical
plants. Key features of our Smartline solutions include:
• Standard and modular designs, which can be pre-assembled
• Easily transportable
• Lower cost and simple installation
FABPAC Fabric Filters for Particulate Control
These standardized and modular fabric filters can help our customers lower operational cost and
footprint and reduce site installation time. Our patented Optipow* cleaning valves together with
EFFIC controllers provide longer bag life and lower compressed air consumption. FABPAC filters are
available in four standardized sizes with various bag lengths and bag materials.
ELPAC ESPs for Particulate Control
The ELPAC ESP adapts the benefits developed on large units to a smaller scale. Key features include:
covered service room on top, flat bottom with scraper conveyor, Switch Integrated Rectifiers (SIR),
efficient construction for easy access, and large gas flow range with one module
(7000-170,000 m3/hr).
Micro-NID* Technology for Dry Desulfurization
and Multi-pollutant Control
Due to its simple design, our advanced dry desulfurization
technology is also available for small-scale applications. With more
stringent regulations being progressively extended to smaller
units, this type of application is expected to be widely deployed
in the coming years.
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SMALL SIZE AQCSSmartline Solutions
STEAM POWER SYSTEMS PRODUCT CATALOG I Air Quality Control Systems
GE supplied two ELPAC ESPs on a 4 MW boiler and an 8 MW boiler that were firing bio-fuels such as forest residues and wood chips at a CHP project in Norway. Designed for an emission guarantee of 50 mg/Nm3, these ESPs were delivered to the customer within five months and installed in just four weeks. Both units are performing well and achieving emissions lower than what was guaranteed.
FABPACGas Temperatures (°C) 25 - 200
Gas Flow Rate (m3/h) Up to 250,000
Dust Loading at FF inlet (g/Nm3) 2 – 100
Emission at FF outlet (mg/Nm3) 5 - 50, filterable PM only
Availability (%) Up to 99%
ELPACGas Temperatures (°C) 70 - 250
Gas Flow Rate (m3/h) Up to 170,000
Dust Loading at FF inlet (g/Nm3) 1 – 50
Emission at FF outlet (mg/Nm3) Up to 20, filterable PM only
Availability (%) Up to 98%
Micro-NID*
Maximum gas temperature at inlet (°C) 200
Outlet Emission Limit, HCl (mg/Nm3) 2
Outlet Emission Limit, HF (mg/Nm3) 0.3
Outlet Emission Limit, SO2 (mg/Nm3) 5
Outlet Emission Limit, Particulate (mg/Nm3) 5
Outlet Emission Limit, Hg (mg/Nm3) 0.03
Outlet Emission Limit, Dioxin (ng/Nm3) 0.05
Maximum Gas Flow rate (Nm3/h) 10 0001
1 For higher gas flow rates, standard NID will apply.
Powering the World
In addition to addressing the most common pollutants, such as particulate
matter, SOx and NOx, GE offers solutions for capturing other pollutants.
Mercury
The Filsorption* system uses activated carbon injection upstream of a
standard primary or secondary particulate control system.
The Mer-Cure* system uses a proprietary approach injection of sorbent
upstream of the air preheaters, for faster oxidation under higher temperatures.
• More than 25 years and 29 GW installed
• More than two million hours of reliable operation
Volatile Organic Compounds (VOC)
For VOC mitigation, GE provides thermal oxidizers and regenerative thermal
oxidizers – mature technologies that have been sold for many decades.
Zero Liquid Discharge (ZLD)
Additionally, GE offers our Spray Dryer Evaporator (SDE*) solution for plants
operating WFGD technologies to achieve Zero Liquid Discharge (ZLD). Our
simple and cost effective SDE technology uses hot flue gas to evaporate
waste water. The dissolved or suspended solids are collected in existing
particulate removal equipment. With the addition of lime to condition the
waste water feed stream, acid gases in the flue gas can be captured as
an added benefit.
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STEAM POWER SYSTEMS PRODUCT CATALOG I Air Quality Control Systems
OTHER AQCS SOLUTIONSMercury, VOC, Zero Liquid Discharge
MERCURY CONTROLFilsorption* for Power (typical)
Parameter Number
Fuel Boiler flue gas
ReagentActivated carbon or activated lignite coke and/or non-carbon sorbents
Bromine InjectionOptional depending on the halogen content in the coal
Removal Efficiency (%) Up to 92
Temperature (°C) 200
PAC Addition Rate (kg/106 Nm3/h)
50 - 200
ZERO LIQUID DISCHARGE SDE* for Power (typical)
Parameter Number
Evaporation Rate (m3/h) 5 - 35
Wastewater TDS (mg/l) Up to 140,000
Wastewater TSS (%) Up to 20
Gas Flow Rate (Nm3/h) Up to 175,000
Max Inlet Temperature (°C) 400
Load Range per Module (%) 30 - 100
Availability (%) Up to 97
VOC CONTROLThermal Oxidizer
Parameter Number
Gas Flow Rate (Nm3/sec) 0.2 – 20
VOC Concentration (% of LEL) 0 – 25
Load Range (%) 33 – 100
Dust Load (mg/Nm3 wg) Max 2.0
Operating Temperature (°C) 760 – 900
Oxygen content in Process Gas (%) 10 – 21
VOC Destruction Efficiency – Applicable for VOC Content Between 1000 ppm and 25% LEL (%)
Max. 99.5
VOC Emission Applicable for VOC content below 1000 ppm (ppm)
Min. 5
Availability (%) Up to 98
Regenerative Thermal OxidizerParameter Number
Gas Flow Rate (Nm3/sec) 0.5 – 50
VOC Concentration (% of LEL) 0 – 25
Load Range (%) 33 – 100
Dust Load (mg/Nm3 wg) Max 2.0
Operating Temperature (°C) 815 – 1,000
Oxygen content in Process Gas (%) 8 – 21
VOC Destruction Efficiency – Applicable for VOC Content Between 1000 ppm and 25% LEL (%)
Up to 95 - 99.5
VOC Emission Applicable for VOC content below 1000 ppm (ppm)
Down to 5 - 50
Availability (%) Up to 98
Powering the World
Success Story
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STEAM POWER SYSTEMS PRODUCT CATALOG I Air Quality Control Systems
SOLUTIONS FOR EXISTING AQCS
A Brazilian customer replaced its conventional T/R sets with new high frequency power supplies (SIR) and control systems (EPIC). Emissions at the stack were reduced from 80 mg/Nm3 to 40 mg/N m3. Furthermore, the reliability of the equipment improved significantly, as did system life.
Plant operators today face various challenges such as cost reduction, compliance with more stringent environmental regulations, and the need for improved plant flexibility. With an understanding of these challenges, GE uses our knowledge of AQCS technology and continues to innovate, offering a full range of:
• Upgrades and retrofit solutions for our customers’ existing AQCS equipment
• Services and parts for operation and maintenance
Some of our key solutions for enhancing performance of existing AQCS include:
• High-frequency power supplies - switch integration rectifiers (SIRs) for ESPs
• Emissions and energy optimization algorithms, like EPOQ software, for various AQCS equipment types
• Advanced control systems - EPIC for ESP and EFFIC for fabric filters
• Superior diagnosis using ProMo software
SIR Technology
Our SIR technology combines a transformer/high
voltage rectifier (T/R) and a control system for energizing
and controlling ESPs in one compact integrated unit.
With an integrated rapping control and EPOQ software
for pulse optimization, the SIR controller takes the ESP’s
performance to the next level.
Key Features• Suitable for installation on new or existing ESPs
from GE and also other OEMs
• More than 3,500 SIR units in operation around the world; solution developed in the 1990s
• Reduces up to 70 percent particulate emissions compared to conventional technology, and emission levels reduced down to below 20 mg/Nm3, when required
• Determines top power consumption
• Avoids cost-intensive retrofit
• Suitable for ESPs in power and industrial applications, such as cement and pulp & paper
Sulfite Analyzer for WFGD
Our new patented solution provides real-time
measurement and control of the sulfite
concentration in the slurry, allowing for reduced
power consumption from the blower. Designed to
cope with harsh environments in heavy industrial
applications, our Sulfite Analyzer can be installed in
the existing slurry slip stream with no need for an
outage or process alteration.
Switch Integrated Rectifiers (SIR)Model SIR4 120 kW SIR4 102 kW
Sizes Available HV70 kV – 1700 mA, 85 kV – 1400 mA, 100 kV – 1200 mA
70 kV - 1500 mA, 85 kV - 1200 mA
Power Supply Input (3-phase rectifier)
50 Hz 400 V - 196A, 500V - 157 A 380 V - 180A, 400 V - 175A60 Hz 480 V -163 A, 575 V - 136A 480 V - 146 A
Operating Temperature -40ºC to +40ºC max 50ºC with reduced output current
-25ºC to +40ºC max 50ºC (122ºF) with reduced output current 45ºC with nominal output for 480 V, 60 Hz
Size (w x d x h) 845 x 1300 x 1210 mm (33,3 x 51,2 x 47,6 in)Weight 450 - 500 kg
Dielectric TypeMineral Transformer Oil Nynas Nytro 10XN, vacuum degasified
Solutions for performance improvement of existing AQCS Equipment – GE & Other OEMsProduct Equip-
ment Functionality Key Benefits
SIR ESP ESP Power Supply Emission & energy optimization
EPIC ESP TR Controller Emission & energy optimization
ERIC ESP Rapper Controller Control of electric impact rappers
EFFIC FF FF Controller Air consumption & bag life enhancement
Optipow FF Pulse Valve Superior pulsing performance for bag cleaning
ProMo4 ESP/FF/FGD Monitoring & Control Software Performance tuning & analytical tool, remote connectivity
ETU ESP/FF/FGD Human Machine Interface Hand-held unit for controller settings, input & display
PCETU/PCMTU ESP/FF/FGD Human Machine Interface PC-based unit for controller settings, input & display
IM300 ESP/FF/FGD Protocol Convertor Flaktbus to ethernet converter
AGDMS ESP Gas Distribution(GD) Measurement Tool Robotic device for automated gd measurement
Ammonia Injection Skid ESP Ammonia Injection in Flue Gas Stream Performance improvement of esp using ammonia injection
Powering the World
Success Story
Products
APPLICATIONParticulate -FF
Particulate -ESP
DeSOx- DFGD
DeSOx- WFGD/ SWFGD
DeNOx- SCR
VOC- TO / RTO / KemPAK
Mercury - Mercure /Filsorption
Oil & Gas
FCCU P P P P
Boilers/Heaters P P P P P
Tank farms/Odour/Flares P P P P P
Captive Power P P P P P P
Sour Gas Incineration P P P P P
Catalyst Recovery Unit P P P P
SRU/TGTU P P P P
Waste To Energy Incinerators P P P P P P
Iron & Steel
Iron Ore Sintering P P P P
Iron Ore Pelletization P P P P
Sponge Iron Kiln P P P
Stock House Ventillation P P
Cast House Ventillation P P
Auxiliary Dedusting P P
Induction Furnace P
Electric Arc Furnace P
Blast Furnace P
Boilers/ Captive Power Plant P P P P P P
Cement
Cement Kiln P P P P P
Cement Mill P P
Clinker Cooler P P
Coal Mill P P
Auxiliary Dedusting P P
Boilers/ Captive Power Plant P P P P P P
Pulp & Paper
Soda Recovery Boiler P
Lime Kiln P P
Biomass Boilers/Heaters P P P P P P
Non- Ferrous
Smelter P P
Converter P P
Auxiliary Dedusting P P
Aluminum
Non-Ferrous Metal
Iron/Steel
Pulp and Paper
Waste to Energy
Biomass PetrochemicalsOil and Gas
Cement
8 Industries Covered
GE’s advanced Air Quality Control Systems are also used in a variety of industrial applications, including
iron and steel, cement, waste-to-energy, biomass, pulp and paper and non-ferrous metals. At GE we
address pollutants such as particulates, SOx, NOx, acid compounds, heavy metals, dioxin and furans.
Additionally, we have developed special products to mitigate emissions such as HAPs (Hazardous Air
Pollutants), VOCs (Volatile Organic Compounds) and H2S.
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STEAM POWER SYSTEMS PRODUCT CATALOG I Air Quality Control Systems
AQCS FOR INDUSTRYSolutions for Industrial Applications
A leading cement manufacturer in India decided to expand its cement plant in the Indian state of Rajasthan. The manufacturer chose our AQCS equipment including Raw Mill Kiln Reverse air bag house, Clinker Cooler ESP, and Coal Mill fabric filter, all of which are designed for emissions of 30 mg/Nm3. The equipment was successfully commissioned along with the entire plant in 2015.
Key Benefits• Technically reliable and cost-effective solutions
• Product expertise leading to solutions that meet customer requirements
• Waste to energy: tailored and efficient solutions to help meet the most stringent emission requirements to both air and water, and at the same time recover valuable energy
• Pulp and paper: advanced ESP and fabric filter technology applied worldwide for emission compliance
• Iron, steel and non-ferrous: primary and secondary steelmaking (coking plants, sintering plants,ore beneficiation, pig iron production, oxygen steel plants, electric arc furnaces, rolling mills) as well as smelting furnaces and converters for various non-ferrous productions
• Petrochemicals-oil and gas: allowing the petroleum and refining industry to conform to strict emission limits while processing a broad feedstock slate
• Cement: single source for cement industry for multi-pollutant emission control with proven technologies such as FF, ESP and FGD systems
Powering the World
Key Demonstration Projects
Oxy-Combustion• 30 MWth, Germany (lignite)• 30 MWth, France (gas)• Boiler Simulation Facility, 15 MWth, U.S. (coal)• Mobile GPU Unit
Post-CombustionChilled Ammonia Process• 5 MWth, Sweden (oil)• 40 MWth, Norway (gas & FCC �ue gas)• 58 MWe, U.S. (coal)• 5 MWth, U.S. (coal)
Post-CombustionAdvanced Amines Process• 5 MWth, France (coal)• 2 MWth, U.S. (coal)
STEAM POWER SYSTEMS PRODUCT CATALOG I CO2 Capture Solutions
CO2 CAPTURE SOLUTIONS (CCS) Building a Low Carbon Future
As a leader in the development of both cleaner coal technologies and Air Quality Control Systems, GE is at the forefront in the development of carbon capture technologies. With an intensive research and
development program, we have designed and constructed 13 CO2 Capture Solutions (CCS) demonstration projects around the world, and these technologies are ready for large-scale implementation.
Given the variety of plant types and fuel combinations in operation today, GE’s portfolio of technologies provides our customers with solutions that take into account many variables, including installation costs, overall plant efficiencies, and operation and maintenance costs. Our CCS technologies offer both post-combustion and oxy-combustion solutions for applications covering new build plants and the existing installed base. Additionally, our post combustion technologies can be scaled down for industrial flue gas from sources such as steel mills, cement factories, refineries and chemical plants. We are also developing second-generation technologies such as Regenerative Calcium Cycle (RCC) and Chemical Looping Combustion (CLC).
What We Offer
Our CCS services range from concept engineering and feasibility studies to plant commissioning. Our
full scope of solutions includes design, equipment supply, installation, power block system integration,
CO2 capture and processing equipment, and the full power plant. We make sure our customers have
everything they need, including cost control, quality control, health and safety and O&M training.
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Powering the World
• All types of offerings for
oxy- and post-combustion
technologies
• Most comprehensive pilot/
demo portfolio
• Reliable technologies,
ready for scale-up
STEAM POWER SYSTEMS PRODUCT CATALOG I CO2 Capture Solutions
OXY-COMBUSTION CO2 CAPTURE
82 83
Oxy-combustion consists of burning fossil fuels in a mixture of pure oxygen and re-circulated flue
gas, resulting in CO2-rich flue gas (free of nitrogen, contrary to conventional air-fired power plants).
The pure oxygen is supplied by a cryogenic air separation unit (ASU).
Oxy-combustionTarget (estimated future commercial) Status (today’s offering)
Boiler Type Two-pass, tower Two-pass
Fuel
• Bituminous, sub-bituminous• Lignite• Oil, gas• Biomass (part load)
• Bituminous, sub-bituminous• Biomass (part load)
Size Up to 1,350 MWe Up to 448 MWe
Steam Condition• Ultra-supercritical• Up to 605°C/623°C/300 bar
• Ultra-supercritical • Up to 605°C/623°C/279 bar
Gas Processing UnitParameters Target (estimated future commercial) Status (today’s offering)
Temperature (°C) 20 – 100 20 – 100
Pressure (bars) 1 1
Flow Rate (t/h) 1,400 Up to 875
C02 Vol (% dry basis) 70 – 95 70 – 95
H2O Vol (%) 2 – 25 2 – 25
N2 Vol (% dry basis) 2 – 5 2 – 5
O2 Vol (% dry basis) 20 – 50 20 – 50
C02 Capture Rate(%) 90 90
C02 Product Specification and Conditions
Temperature (°C) As Required As Required
Pressure (bars) As Required As Required
Flow Rate (t/h) Up to 600 Up to 276
C02 (mol-%) > 95 – >99 Depending on Need > 95 – >99 Depending on Need
H2O (mol-ppm) As Required As Required
Key Benefits • Reliable and robust process
• Adaptable to most boiler and fuel types with the potential for rapid scale up, even up to the 1,000 MWe range
• Operational flexibility options
• Available for retrofit to existing power plants
• Integrated GE approach, providing both technical and economical benefits
The oxy-combustion boiler has been under development for more than a decade, starting with research and the subsequent establishment of a laboratory pilot in the 1990s. GE has been at the forefront of oxy-combustion development, and we:
• developed the first oxy pilot plant at a site in Germany
• demonstrated the entire oxy-technology chain including a gas processing unit in the boiler simulation facility located in Windsor, Connecticut, USA.
GE is also developing the gas processing unit (GPU), which is designed to further treat and process the flue gas downstream of the oxy-boiler, delivering CO2 at the required specification. As part of the validation program, a mobile pilot unit was built for testing under multiple oxy configurations.
Oxy-combustion, a flexible technology for all types of fuel
ASUAirSeparationUnit
oxy-Boiler ESP/Bag FilterDust elimination
FGD Desulphurization
GPU Gas Processing Unit
CO2 Storage
FGC Flue Gas Condenser
Nitrogen
Coal Mill
Powering the World
POST COMBUSTION CO2 CAPTURE Chilled Ammonia Process (CAP)
The chilled ammonia process (CAP) is a proprietary technology being developed by GE. Field validation
tests have successfully demonstrated more than 99.9 percent pure CO2 product quality at 90 percent
capture rates on combustion flue gas originating from oil, gas, and coal fuels. CAP features include:
• High CO2 product purity
• CO2 capture process tolerant to oxygen and flue gas impurities
• Stable reagent, no degradation or emission of trace contaminants
• Low-cost, globally available reagent
• Ability to use low ambient conditions to further reduce the energy consumption of the process
• Integrated approach from GE, providing both economic and technical benefits
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NOTE: Regenerator pressure at 20 bara
STEAM POWER SYSTEMS PRODUCT CATALOG I CO2 Capture Solutions
Environmentally benign in terms of emissions, CAP is a chemical absorption process using an ammonium-based aqueous solvent. The flue gas is contacted with chemical solvent – forming ammonium bicarbonate, ammonium carbonate and ammonium carbamate. The chemical reactions are reversible, and raising the temperature and the pressure of the reaction products reverses the capture reactions, releasing CO2 and allowing the solvent to be regenerated and returned to the process.
CAP technology can be applied to various types of power plants such as coal, gas and biomass, as well as a vast range of industrial processes emitting CO2. The technology uses ammonia for the solvent, which is a globally available, low-cost commodity chemical with excellent thermal and chemical properties.
CAP
Parameters Target (estimated future commercial) Status (today’s offering)
Flue Gas Inlet Conditions
Temperature (°C) 45 – 100 45 – 100
Pressure (bara) 1 1
Flow Rate (t/h) Up to 3,000 Up to 1,150
C02 Vol (% dry basis) 4 – 16 4 – 16
H2O Vol (%) 5 – 10 5 – 10
N2 Vol (% dry basis) 70 70
O2 Vol (% dry basis) 2 – 6 2 – 6
C02 Capture Rate (%) Up to 90 Up to 90
CO2 Product Specification and Conditions
Temperature (°C) As Required As Required
Pressure (bara) As Required As Required
Flow Rate (t/h) Up to 800 10 – 200
C02 (mol-%) Up to 99.9 Up to 99.9
H2O (mol-ppm) As Required As Required
CAP, a state-of-the-art CO2 capture technology
Flue Gas Cooling/conditioning
CO2 Absorption CO2 Regeneration
CO2 Storage
Powering the World
Amine-based carbon capture processes have been proven for decades in natural gas and syngas purification.
Our Advanced Amine Process (AAP) applied to flue gases was developed jointly with Dow Chemical Company.
Some key benefits of this process include:
• More energy efficient capture and compression of the CO2 product
• Designed for stringent emissions mitigation and control
• Less solvent degradation than Monoethanolamine (MEA), leading to lower chemical consumption
and lower production of effluents and waste
• Adaptable to new and installed base for both coal- and gas-fired plants
• Higher tolerance against oxygen and trace contaminants
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STEAM POWER SYSTEMS PRODUCT CATALOG I CO2 Capture Solutions
AAP
Parameters Target (estimated future commercial) Status (today’s offering)
Flue Gas Inlet Conditions
Temperature (°C) 30 – 100 30 – 100
Pressure (bara) 1 1
Flow Rate (t/h) Up to 4,000 Up to 1,150
C02 Vol (% dry basis) 3 – 15 4 – 15
H2O Vol (%) 5 – 30 5 – 30
N2 Vol (% dry basis) 70 – 90 70 – 90
O2 Vol (% dry basis) 3 – 10 3 – 10
C02 Capture Rate (%) Up to 90 Up to 90
CO2 Product Specification and Conditions
Temperature (°C) As Required As Required
Pressure (bara) As Required As Required
Flow Rate (t/h) Up to 800 12.5 – 230
C02 (mol-%) > 99.5 – 99.9 > 99.5 – 99.9
H2O (mol-ppm) As Required As Required
The flue gas is bound with the chemical solvent – Advanced Amine – which binds selectively to the flue gas CO2. Raising the temperature reverses the capture reaction, releasing CO2 and allowing the solvent to be recycled.
The technology has been demonstrated successfully in the field at 90 percent capture rates. Based on the low physical solubility of N2 and O2 in aqueous amines, CO2 product purity is greater than 99.5 percent after CO2 compression and dehydration. The highly selective reaction with CO2 is an important advantage of any alkaline scrubbing process and distinguishes this process from the results obtained from physical solvents, membranes or adsorbents.
Flue Gas Cooling/conditioning
CO2 AbsorptionCO2 Regeneration
CO2 Storage
Optimization of a well-known process for a new application
Powering the World
POST COMBUSTION CO2 CAPTURE Advanced Amine Process (AAP)
Our Customers Determine Our Success.
POWER
TRANSPORTATION
ENERGY MANAGEMENT
AVIATION
OIL & GAS
HEALTHCARE
APPLIANCES & LIGHTING
Combustion science & services, installed
base
Electrification, controls & power conversion
technology
Services & technology — a first-mover in growth regions
RENEWABLE ENERGY
Clean and productive Wind and Hydro
power generation services
GLOBALRESEARCH
GLOBALGROWTH
ORGANIZATION
DIGITALCULTURE &
SIMPLIFICATION
Advanced material, manufacturing &
engineering productivity
Engine technology & localization in growth regions
LED — a gateway to energy efficiency
Diagnostics technology — a first-mover & anchor
in growth regions
The GE StoreDRIVING COMPETITIVE ADVANTAGE ACROSS OUR BUSINESSES
We drive enterprise advantages that benefit the entire company through what we call the “GE Store.” It means that every business in GE can share and access the same technology, structure and intellect. The value of the GE Store is captured by faster growth at higher margins; it makes the totality of GE more competitive than the parts. No other company has the ability to transfer intellect and technology the way GE can through the Store.
Steam Power Systems: Powering the World
* Trademark of General Electric Company.
GEA31876 (08/2015)